High-Voltage Safety Devices
Key components in battery (BEV), fuel cell (FCEV) and hybrid (PHEV) electric vehicles
High-voltage (HV) systems with voltages up to 1000 VDC have become a key component in battery (BEV), fuel cell (FCEV) and hybrid (PHEV) electric vehicles, by substantially improving the efficiency of modern vehicles through faster charging and enhanced range. In modern architectures with such high voltages and peak currents up to 1.5 kA nominal and up to 25 kA in case of a short-circuit, reliable and safe solutions are necessary for rapid switching of high-voltage circuits under normal operating modes as well as under emergencies.
Apart from automotive, high-voltage circuits are widely used in several other industry sectors, requiring high-end solutions to guarantee system functionality and safety.
Rheinmetall offers best in class high-voltage switches in terms of functionality, cost and weight, addressing the challenging requirements of high-voltage circuits in modern automotive and non-automotive applications. Due to their high degree of flexibility, the Rheinmetall switches can be easily adapted to all customer requirements.
The Rheinmetall DC HV contactor ensures the safe and reliable operation of BEV, PHEV and FCEV vehicles, by disconnecting the battery or the DC fast charging plug when not in use or in case of emergency. It is capable of carrying and breaking high currents bidirectionally.
Samples available upon request!
HIGHLIGHTS
- Best-in-class weight and cost (<300g)
- Non-pressurized arc chamber: Avoid bursting or leakage over lifetime and enable high contact temperatures (thus allow for smaller busbar cross-sections)
- Sealed design for dust and water protection (IP6K9K) and avoiding gas outburst
- Withstands > 20 kA short circuit without bursting
- Silver plated contacts for high weld and low contact resistance over lifetime
- High shock resistance (>60 g) and durability (> 300,000 cycles)
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Technical Data |
Rheinmetall DC HV Contactor |
|---|---|
|
Operating voltage |
450 – 1500 VDC |
|
Operating currents |
< 750 A cont. |
|
Contact resistance |
< 80 µΩ |
|
Limiting break current |
850 V / 2000 A (1-2x) 850 V / 600 A (10x) 750 V / 800 A (10x) 850 V / 5 A (100,000x) |
|
Break time under load |
< 10 ms |
|
Power consumption |
< 2 W |
|
Weight |
< 300 g |
The Rheinmetall Pyrofuse plays a key role to safety in BEV, PHEV and FCEV vehicles by rapidly disconnecting the battery or the DC fast charging plug in case of critical situations (e.g., vehicle crash or short circuits).
Samples available upon request!
HIGHLIGHTS
- Rapid galvanic separation by pyrotechnic actuator (< 1 ms)
- Minimal power loss & thermal self-heating due to best in class resistance
- Gas-tight – No outburst of conductive and hot gasses
- High shock resistance (>60 g)
- Compact and low weight design
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TECHNICAL DATA |
Rheinmetall DC HV Pyrofuse |
|---|---|
|
Rated voltage |
450 – 1500 VDC |
|
Rated current |
< 750 A |
|
Temperature range (storage, operation) |
-40 °C to 85 °C |
|
Limiting break current |
15,000 A (850 V / 25 µH) 18,000 A (850 V / 15 µH) 12,000 A (850 V / 110 µH) |
|
Short-circuit break time |
< 1 ms |
|
Resistance |
< 26 µΩ |
|
Insulation resistance (HV-HV) |
> 50 MΩ (4500 V DC) |
|
Weight |
< 300 g |
Opposite to the Rheinmetall Pyrofuse, the HV Discharger (also known as HV Pyro-Closer) short-circuits rapidly and permanently high-voltage circuits in critical situations (e.g., vehicle crash or malfunctions). Example applications are the rapid discharge of DC-link capacitors in case of a crash, or the rapid consumption of hydrogen by short-circuiting the fuel cell terminals in case of emergency.
Samples available upon request!
HIGHLIGHTS
- Rapid and safe electrical connection by pyrotechnic actuator (< 1 ms)
- Low resistance after operation: Allow high discharge currents to quickly ensure a safe state
- Compact and low weight design
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TECHNICAL DATA |
Rheinmetall DC HV Discharger |
|---|---|
|
Operating voltage |
450 – 1500 VDC |
|
Peak current |
< 4 kA for 5 ms |
|
Electrical resistance after actuation |
< 10 mΩ |
|
Switching time |
< 1 ms |
|
Temperature range (storage, operation) |
-40 °C to 85 °C |
|
Weight |
< 20 g |