IAA 2017: Leoni presents scalable Y-power distribution units for high-voltage wiring systems

Modular structure approach for distributor components – low-voltage and high-voltage products from a single source – dynamic development of business in the area of electromobility

Nuremberg – Leoni presents the next generation of its modular system for high-voltage power distribution in electric and hybrid vehicles at the IAA International Motor Show in Frankfurt (stand D40 in hall 4.1). As a system partner, Europe's leading supplier of cables and cable systems for the automotive sector and other industries has responded to its customers’ needs: the further developed Y-splitter is more variable, lighter and less expensive than comparable products.

Reliable and space-saving, the product is capable of handling the distribution of power to several high-voltage units – something that is becoming increasingly necessary in HV architectures. A multi-layer, firmly sealed hybrid casing made of metal and plastic exceeds customers’ mechanical and EMC requirements and ensures resilience to environmental impact.

Computer simulations and optimised 3D design were also used to achieve significant improvements in the unit in terms of size, weight and cost. What is more, the modular design enables variable deployment: with parts that are identical in some cases and based on the same structural principles, it is possible to cater for different wire sizes, outlet directions and numbers of outputs (variant: X-power distribution unit).

Presented at the IAA International Motor Show for the first time, the product is designed for two-core shielded high-voltage silicon cables with a cross section of 2 x 6 mm², allowing for higher temperatures. Moreover it is also adaptable for various performance levels and materials. The simple structure of the unit allows it to be scaled to other cross sections such as 2 x 2.5 mm² and 2 x 4 mm² as well as single-core cables. It can also be adapted to customer needs in terms of temperature resilience. The unit is currently designed for 1,000 voltages.

Dynamic development of business with high-voltage products

For more than 15 years, Leoni has been investing in electromobility as an area with a promising future. This is now beginning to pay off: the company received incoming orders worth approx. EUR 400 million in the Wiring Systems Division alone in 2016. Trade in alternative drive technologies is seeing dynamic development, especially on the Chinese market. “Leoni will be expanding its high-voltage production capacity in Shanghai before the end of this year so as to be able to supply local and international customers with high-voltage solutions produced on site,” says Martin Stüttem, Member of the Board of Directors of Leoni AG with responsibility for the Wiring Systems Division.

Leoni has interlinked its portfolio of conventional wiring systems and high-voltage products more closely so as to underscore its standing as a system provider: customers receive cable harnesses for all voltage levels from a single source, thereby simplifying wiring in hybrid and electrically-powered vehicles – in particular with a view to optimising installation space.