THERMAL MANAGEMENT · ELECTRIC VEHICLE · COOLING SYSTEM
Thermal Management: Pre-assembled Hoses for the Cooling Circuit and Battery
We develop and manufacture custom-designed cable assemblies and connection systems according requirements for continuous vibration, temperature fluctuations, and exposure to various media, while ensuring a reliable tightness.
Thermal Management and Heat-Resistant Cables—the battery will only last as long as the temperature allows.
A high-voltage battery operates within a narrow temperature range. If it gets too hot, it ages faster. If it gets too cold, its charging performance decreases. The thermal management system regulates both of these factors using valves, pumps, and sensors. Each of these components requires a connection that is resistant to the fluids it handles, meets high standards for thermal cycling and leak tightness, and can withstand continuous vibration.
KE Elektronik manufactures the corresponding wiring harnesses and connector systems. Connector plugs, including their gaskets, are automatically overmolded in production cells, in some cases directly onto the stamped mesh. Strain relief and longitudinal watertightness are achieved in the same process step rather than through subsequent assembly. Performance is tested in the company’s own laboratory according to specifications, standards, and regulations.
- Thermal management modules and coolant distributors
- Battery cooling and battery management
- Electric coolant pumps and valves
- Temperature and pressure sensors
- Heat pump and interior climate control
Thermal Management
In conventional internal combustion engines, engine cooling must be maintained regardless of the vehicle's environment—whether in arctic cold or tropical heat. Maintaining the ideal operating temperature helps optimize fuel economy and reduce emissions.
In modern electric vehicles, however, temperature control of the high-voltage battery—for example, for preconditioning as part of a modern charging management system—is becoming increasingly important. Maintaining a consistent temperature is essential for extending the service life of the components.
- Connection of cooling and ventilation units
- Battery Thermal Management System (BTMS)
- Interior Climate Control (HVAC)
Your point of contact for plastics, wiring, and connectors—even in high-temperature applications.
Thermal management components rarely fail due to a single component. They fail at the interface between the plastic part, the contact, and the wire. KE Elektronik handles all three areas in-house: plastic manufacturing, wire processing, and assembly and connection technology.
Projects are carried out according to APQP, from concept prototypes to mass production. Tooling, test fixtures, and automation systems are manufactured in-house. If a requirement changes, we modify the equipment without having to wait for external suppliers.
To ensure quality, we perform thermal cycling, leak, and tensile tests, as well as microstructure analyses. Sampling and validation are conducted in accordance with your specifications and are fully documented and traceable.
Ready for your next project?
Talk to our team about your needs — from feasibility studies to mass production.