HV Coupling System

Power meets Safety 

Customer Challenge:

As a vehicle or mobile machine manufacturer, you must provide a safe, pluggable HV connection for an electric vehicle (e. g. eTruck) or an electric mobile machine (e.g. eTractor) to removable HV consumers (e. g. eTrailers or eImplements) or to removable external HV sources (e.g. switchable range extenders, switchable power banks or eTrailers with recuperation)

In addition to the suitable HV socket, you must also implement the active HV safety functions and optional conversion of different HV voltage levels for the safe operation of this pluggable HV connection.

Our Solution:

The DINTEC HV coupling system provides a validated and easy-to-integrate HV subsystem that enables the connection, operation and isolation of two separate HV systems for uni- or bidirectional electrical power transfer. It includes: 

  • an HV coupling module with contactors, pre- and discharge function and sensors,
  • a coupling control unit for coordinating the HV connection setup, monitoring operation and the controlled decoupling process of the two HV circuits,
  • an optional HV DC/DC converter for voltage equalization of two HV systems, 
  • a LV wiring harness that networks the control interface of the e-vehicle and the components of the coupling system with each other, and 
  • an HV cable set for connecting the HV interface of the eVehicle (ePTO) with the coupling module and the HV socket.

HV Coupling Module

The HV coupling module provides the main HV switching an sensing functions.

 

Typical Application

eTrucks

eTractors

eTrailer & eImplements

eRange Extender

Options


Integrated voltage conversion


Expand the coupling system with a DC/DC converter to couple two HV systems with different HV levels or two active HV systems (e.g. range extender for e-vehicles).

Integrated control panel

 
Expand the coupling system with an operating panel to enable decentralized control of the HV coupling interface.

 

Customer Benefits and Features

Dedicated coupling control, which receives the higher-level connection instructions from the e-vehicle and handles the detailed coordination of connection set-up and disconnection, as well as the continuous monitoring process.

Preliminary check of the HV safety of the HV circuit to be connected by integrated insulation resistance measurement, unipolar connection and active precharging before all-pole connection of the HV connection by integrated contactors.

Continuous monitoring of voltage, current, temperature and status of the plug connection.

Controlled opening of the HV contactor with subsequent active discharge at the request of the e-vehicle or emergency disconnection, if necessary under load, if the HV plug is unintentionally removed.

Validated compatibility with the standardized electrical high-performance interface 700 V DC / 480 V AC for tractors and machines for agriculture and forestry according to AEF / ISO 23316-2.
An additional DC/DC converter allows the coupling of two KV systems with different voltage levels, or the connection of a further active HV system (range extender). The HV coupling process can be controlled directly using a dedicated HMI.
Defined responsibility for the components contained in the system, the system functions and the interfaces to the eVehicle / eImplement.
Robust and reliable system design and components designed for rugged applications.

Start with the customer – find out what they want and give it to them.

Technical Features and Data

HV grid interface

  • 400 - 850 VDC rated voltage
  • 200 A continuous current
  • 70 - 140 kW

Coupling functions

  • All-pole HV isolating relays
  • Active pre-charging and discharging
  • Current, voltage and isolation measurement

Coupling control

  • Control interface CAN | J1939
  • Power supply 12V | 24 V


DC/DC conversion

  • Bidirectional power transmission
  • Voltage conversion between 400 and 800 VDC 
  • HV low-voltage side 0..520 VDC
  • HV high-voltage side 450..850 VDC

HV implement socket

  • AEF/ ISO 23316-2 HV socket outlet with integrated mechanical disconnection function
  • Alternatives on request

Put your trust in our solutions when it comes to the fast and reliable implementation of pluggable couplings of HV systems for your electric vehicle or electric body.

Contact us in the early phase of your project realization, because we do not see ourselves as a supplier, but as a solution partner for your concerns. 

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