DRÄXLMAIER exhibits its first Multilayer that is ready for production

The mega-trends in the automobile industry, like autonomous driving, connectivity and electro-mobility are placing increasing demands – both on power and data supply in the vehicle and on interiors. Functional safety is also becoming more important. The car of the future will demand reliable solutions – from storing energy to distributing, contacting and fusing, right up to the function itself, like lighting in the interior.

The central element for the power supply of future vehicle generations is the Multilayer developed by the DRÄXLMAIER Group up to series production and it is being presented to the public for the first time at the IZB. It can be integrated as the central element in the on-board wiring system and thanks to its multi-layer structure triggers off EMC field erasure throughout all voltage ranges. Thanks to its material and its form, it offers savings in both space and weight. Intelligent contacting  helps to reduce power loss. Outflows that can be freely positioned and sophisticated body shell mounting make the Multilayer a fundamental element of the on-board wiring system of the future. It makes a decisive contribution to reliable, high-performance, safe power supply, both in electric vehicles and in autonomous driving.

Current battery storage systems need an on-board wiring system that reliably transports the power to wherever it is needed. An ideal addition to the Multilayer in electric vehicles in the next generation high-voltage wiring harness that expands the system boundaries with a solution for connecting the high-voltage wiring harness to the charging socket. This meets all the requirements for thermo management and a reliable charging function.

Safe reliable fusing in high-voltage on-board wiring systems 
The high-voltage control box is designed for connecting the cell package to the high-voltage wiring harnesses. It contains precise measurement and control electronics, which meet the requirements set out by ASIL risk level C, including an integrated thermal management function. Its shunt-based DRÄXLMAIER current/voltage sensor dIUS works at the highest level of precision, while switching and loading procedures can be monitored. Safety in the 48V wiring harness is provided by the dFuseSmart 48 Volt, a 48 volt functional module kit featuring an arc detector, active trip characteristic, differential measurement, sensing, switching and distribution functions. In the low-voltage wiring harness,  the main fuse box made by DRÄXLMAIER supplies electrical consumers with the necessary potential from a central control unit. It operates, distributes and connects the connected wires in the pre-defined way – flexibly by way of variable fuse sizes and assignments.

Patented Friction Welding Technology
Another central module for efficient energy flow is innovative contacting. The DRÄXLMAIER Fast Charging Connector dFCC is an innovative contact system that is marked by high power and impulse resistance for fast charging in connection with the DRÄXLMAIER High Performance Terminal dHPT+19. The friction-welded cable lugs are an alternative to conventional joining processes for contacting aluminum cables. The patented friction welding method creates substance-to-substance bonding of durable, low-ohmic  Al-Cu strand contacts. This method makes it easier to use aluminum wires in energy wiring systems, as it enables simple process control without any auxiliary joining parts and easily-realizable optical  quality testing.

E-Mobility with up to 800 Volt
In hybrid vehicles and E-vehicles, the battery is a key element. The DRÄXLMAIER Group   develops and produces high-voltage battery storage systems with up to 800 volt for plug-in hybrid and electric vehicles. System integration is done independently of the cells and the storage systems have an optimized cooling concept.
DRÄXLMAIER keeps track of the whole system and also makes a battery management system that includes the battery control unit and includes insulation monitoring and thermos management, current and voltage sensor and  cell voltage measurement and control. With that, the Top 100 Supplier provides an integrated system and electronics solution and also enables efficient diagnosis and integration of safety solutions.

Emotional and functional light technologies
Ambient lighting is a particularly striking feature in the vehicle. The Paspol made by DRÄXLMAIER creates an emotional light scenario by means of homogenous linear lighting in laminated surfaces. More than 16 million colors with  8-bit control can be shown in extremely small space with only one RGB LED. It also enables homogeneous, constant light to be spread, even in a plugged variant. Interior lighting is also becoming increasingly important to display vehicle functions or give signals to the driver. Thus, Dynamic Light that runs dynamically along a light guide, is ideal for displaying warnings, because moving light is perceived more quickly.

Find out more about DRÄXLMAIER products at the stand of the DRÄXLMAIER Group at the IZB (Hall 1, stand 1226) and at <link http: www.draexlmaier.com izb>www.draexlmaier.com/izb.