KROCAR Automotive Cables

The right cable as part of your system solution

Customer-orientated Together with our customers we develop cables that are directly tailored to special applications. Kroschu cables are especially characterised by a high level of performance capability, long-lasting reliability and optimal processing properties. Experienced For over a century, our company has developed, designed and produced special cables for diverse fields of application with experience and innovation. Our developments have repeatedly provided markets with important impetus. Development, design and production from one source The in-house material development enables us to make use of a wide range of cost-optimised materials. Specifications such as halogen- and heavy-metal-free are reliably fulfilled. Due to sound expertise, experience and the close contact with our customers, we are able to specify, design and produce the respective optimal cable from a multitude of possible manufacturing methods and material combinations. Optimal cables for your application Our high level of competence in cable design ensures the implementation of all customer requirements in accordance with international standards. This also includes maximum durability with regard to the movement of the cable and optimised interference resistance. International customers Passenger and utility vehicle manufacturers in Europe and overseas are among our customers. Customised logistics concepts ensure the availability of Kroschu cables at the right time and at the right place.

Cost and quality The latest machine technology enables cost-effective production with continuous quality monitoring. Kromberg & Schubert Cable & Wire is certified according to DIN EN ISO 9001, ISO TS 16 949 as well as DIN EN ISO 14001. We produce in an environmentally friendly and resource-saving manner by conviction, with success. Developmental partner of the automotive industry Kroschu is an experienced and capable partner of the automotive industry. New standards are actively co-designed through co-operation in various working groups. Together with system suppliers, cables developed with original equipment manufacturers (OEM) are brought to series production. The main emphases of development in addition to reliability and performance capability are always the particularly efficient processing of cables on automatic assembly lines. We are an innovative partner. For instance, the chemically cross-linkable 150 C material KROTHERM Flex 10 developed by Kroschu offers a clearly more cost-effective alternative than conventional, irradiation cross-linked solutions. KROTHERM Flex 10 has been produced in series for various automotive applications for several years.

Realised solutions safety multimedia drive/chassis utility vehicles hybrid vehicles

Safety
The developments of the past years were directed at increasing safety and comfort. Kromberg & Schubert have decisively influenced the further development of ABS (wheel speed sensor) cables in recent years. A decrease of cable diameter and reduction of copper cross-sections resulted in considerable cost and weight reductions. For decades, ABS cables of the highest quality requirement have been produced for further processing on fully automatic assembly lines. Releases from all German OEMs and a high level of delivery reliability led to the fact that today, ABS cables from Kromberg & Schubert enter into automotive series production around the world.

ABS for passenger cars

For the corresponding sensors, cable materials within temperature classes C (125 C) and D (150 C) are employed. TPU (PUR) as well as cross-linked materials have become widely adopted.

Realised solutions airbags, sidebags, seat belt tensioners antilock braking system (wheel speed sensor) 125 C / 3,000 h 150 C / 3,000 h brake shoe abrasion electric parking brake night view park distance control (PDC) rear view camera seat adjustments and occupancy tyre pressure monitoring systems (TPMS)

Electric parking brake

For decades, extremely flexible and notch-resistant materials have proved successful a million times for dynamic axle cabling. Depending on the OEM, either TPS or EVA in combination with a TPU (PUR) outer sheath are used as insulation material. Therefore, Kroschu has also qualified the application electric parking brake with these materials. Power cores for the control of brake shoes and signal cores for route and temperature sensors are combined. The permanent dynamic properties of the cables have already successfully been tested in various axle simulation stands so that several OEM have launched series production with our cables in 2010.

New generation of wheel speed sensor cables

The development of a new generation of wheel speed sensor cables that realise cost savings of about 20 % was completed in 2009. At the beginning, particular emphasis was placed upon a reduction of copper use and an economical use of high-quality insulation materials. Unproblematic further processing on fully automatic assembly system must be guaranteed in future as well. Reproducibility and adherence to stripping force requirements with only low tolerances are key issues here. Due to the selection of conductor designs that have specially been optimised for use in axle cabling, Kroschu succeeded in considerably exceeding the mechanical requirements (vibrations) of the current series solution. Savings of 30 % in copper, 25 % in insulation material and 40 % in sheathing material were achieved. The new wheel speed sensor cables are not only cost-effective but do also withstand higher mechanical stress and preserve valuable raw material resources.

Drive / Chassis
As a result of the increasingly more powerful engines and gearboxes, the temperature requirements imposed on the insulation materials also increased. Kromberg & Schubert responded to these demands concerning engine and gearbox management with the development of 150 C cables. In this respect, single cores as well as sheathed cables are used here, which are qualified for the respective requirement in temperature and media resistance.

Engine
The cabling of powerful engines of the latest generations necessitate insulation materials with highest temperature requirements. Especially fluoroplastics that are also media-resistant are employed.

Gearbox
Modern automatic gearboxes with Tiptronic circuits enable continuous transition of the switching states. They increase driving comfort and reduce wearing. Special sheathed cable solution with our 150 C material KROTHERM Flex 10 exist for these applications.

Realised solutions active steering comfort gearbox crankshaft sensors dynamic anti-shock control fuel injection pumps high-temperature knocking sensors rear axle steering variable valve train

Steering
New concepts improving driving comfort have been developed such as active steering. In addition to hydraulic-mechanical steering gear, active steering also has a planetary gear with electric control. The development of the required cable was carried out in co-operation with Kromberg & Schubert. The demanding requirements concerning electromagnetic compatibility are realised by a particular screening technology.

Alternative drives
Electromobility
The rapidly increasing energy demand of the world population and the finite resources of fossil fuels force global markets of the automotive industry to increasingly focus on electrically powered vehicles, away from combustion engines. This process is marked by diverse interim solutions of hybridisation. How quick total electromobility can be achieved depends on the development of more efficient batteries with a considerably higher energy density at market-orientated prices, a new infrastructure for recharging batteries and, last but not least, the acceptance of the people.

Micro Hybrid Combustion engine Combustion engine

Mild Hybrid Combustion engine

Full Hybrid Combustion engine

Plug-in Hybrid Combustion engine as range extender Electric motor Electric motor

Start / Stop Parallel drive Energy storage Fossil fuels Fossil fuels Fossil fuels Storage capacitor Combustion engine Increasing level of electric mobility Parallel drive Fossil fuels Storage batteries Serial drive Storage batteries Fossil fuels Electric motor Storage batteries Realised solutions power cables up to 200 C / 3,000 h control cables up to 200 C / 3,000 h

Fuel cell, primarily electrically powered vehicles

Currently, alternative drive systems such as fuel cells, electric vehicles or hybrid drives with various stages of expansion are major issues in development at all OEM. For all these developments, power cables are required for electric drive engines as well as high-voltage cables for single aggregates such as oil pumps, air-conditioning compressor or charging cables for electric energy storage. Kroschu offers cable solutions according to LV 212 temperature class B* (105 C / 3,000 h) up to temperature class F (105 C / 3,000 h), depending on the OEM. In this context, the market demands particular silicone compounds with increased tear resistance. Kroschu has already responded to this market development in 2009 and invested in a new IR silicone cross-linking line.
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Electric motor / Energy recovery

Electric motor / Boost

Multimedia
Innovations in the field of electronics concerning increased comfort, driving safety and drive systems necessitate the development of new, more reliable data cables. For this purpose, Kroschu has developed cables with particularly high demands on the electrical and mechanical properties that were brought to series production together with various OEMs. The cables are utilised in on-board systems for temperature class B* (105 C / 3,000h) as well as in the engine compartment for temperature class C (150 C / 3,000h).

Aerials
For the increasing demand in aerial cables, the OEM in co-operation with Kromberg & Schubert developed a 50 Ohm (audio) and 75 Ohm (video) coaxial cable which meets the requirements of on-board electronics. Smallest measurements, lowest attenuation losses with utilisation temperatures up to 150 C characterise these products. For motional applications, e.g. in the area of the tailgate, we offer highly-flexible special solutions.

Applications
radio, DVD, CD, TV internet, telephone navigation safety technology

Realised solutions aerials Ethernet cameras FlexRay CAN-Bus GVIF/USB car and mobile phones LVDS/CD players 8 EMOST

Star-quad data cables

Screened star-quad designs increasingly replace multi core PVC-sheathed in multimedia applications. At an early stage, Kroschu has also added these cables with their versatile fields of application into its product portfolio. Not only have cables for fixed installation in on-board systems been brought to series production but also cables for dynamic use. These screened cables are applied in areas such as rear view camera systems, display controls or USB connection systems. For reversed-bending tight designs, a PUR sheath enables the utilisation in permanent motion and therefore forms the basis for the compliance with mechanical and electrical properties with narrow tolerances. Moreover, this material is suitable for utilisation at 125 C in the engine compartment. Similarly with regard to flame and media resistance, cables can be designed that meet customary requirements according to LV 212. Cables are designed in such a manner that a secure transmission of data or pictures is possible, despite movements above doors, tailgates or outside mirrors. This results in high demands on mechanical and electrical properties of the cables. Electrical properties such as characteristic impedance, cable attenuation and operating time are the decisive parameters.

FlexRay
is a high-speed communication data bus, which fulfils the safety-related demands in a car. With a data rate of up to 10 Mbit/s, FlexRay aims at applications such as e.g. X-by-Wire or powertrain. From the beginning, Kromberg & Schubert together with OEMs have developed cable solutions for the areas of cable harness and wheel house. The cables are characterised by high temperature stability as well as highest demands on electrical properties.

Utility vehicles
Utility vehicles must have a particularly high availability in an extraordinarily cost-sensitive environment. This places high demands on all components. Built-in cables are also exposed year-round to harsh weather influences as well as splash water and rockfall. Kromberg & Schubert supplies cables for the utility vehicle market which withstand these greater thermal and mechanical demands. ADR/GGVSE approvals for the employed cables exist.

Wheel speed sensor cables for utility vehicles

For the corresponding sensors, cable materials within temperature class D (150 C 3,000 h) are employed. The material combination ETFE- VTPE-O KROTHERM Flex 10 is especially suitable for these increased requirements. As a cost-effective alternative the combination PPS-VTPE-O KROTHERM Flex 10 is also suitable. For both types releases from well-known OEM have been obtained.

AdBlue
AdBlue is an aqueous environmentally friendly chemical (urea solution) which is used for after-treatment of exhaust gases. This method is mainly applied in utility vehicles (particularly in lorries and buses) but is also increasingly used in passenger cars. Therefore, Kroschu offers cables in its portfolio that withstand the chemical requirements.

Engine and gearbox management

Especially in these fields of application, thermal pressure and media influences, such as various oils, lubricants and cleaning fluids, are particularly high. In this context, Kroschu cables with the cross-linked sheathing material VTPE-O KROTHERM Flex 10 are often used. Fluorine polymers as well as the PPS are employed as insulation materials for these cores.
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Trailer cabling
PVC-sheathed cables lying unprotected below the trailer are exposed to extreme environmental stress. Therefore, TPS/TPU (PUR) material combinations can ideally be applied. Cable types containing PVC are also employed in specific areas with lower stress.

Connecting cables
The electrical connection between towing vehicle and trailer is established by spiral cables. For this purpose, Kroschu offers TPU (PUR) coated cables. This material ensures the required restoring force of the coil throughout its entire lifetime.

Lighting system cabling

The complex design of trailers becomes more extensive and also improves safety. Therefore, Kroschu provides cables adapted to this use. Different models are available for these cables, e.g. rectangular solutions.

Realised solutions wheel speed sensor cables 150 C / 3,000 h and 175 C / 15,000 h 11 AdBlue BUS cabling connection between tractor engine and trailer lighting system cabling

Test engineering
Constant controls (inline) as well as exact measurement and acquisition of mechanical and electrical data during the production and on the finished product guarantee the compliance with general and customer-specific testing requirements. Part of the equipment are not only laboratory-technical measuring facilities for determining the material-specific as well as the exact measurement of electrical parameters from the DC range up to 6 GHz on various network analysers. But also a programme-controlled HF measuring facility is available. HF properties of cables are tested in-house in consideration of LV 213-1 and LV 213-2. Kromberg & Schubert were decisively involved in the development of these testing standards as part of a working group.

Material tests
Kromberg & Schubert has an in-house testing laboratory and thus create optimal prerequisites regarding the new and further development of materials and cables.

Thermal tests
Kromberg & Schubert has climatic chambers for the simulation of environmental conditions for instance, as they occur in the engine compartment of a vehicle. For this purpose, humidity and temperature influences can be varied in wide ranges.

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Electrical tests
The signal transmission cables of the latest generation place highest demands on electrical properties. With the help of network analysers, parameters such as characteristic impedance, cable attenuation and near-end crosstalk attenuation can be determined by special measurement programmes throughout the entire frequency range up to 6 GHz.

Mechanical tests
Kromberg & Schubert use reversed-bending testing lines to examine flexible cables with regard to an estimation of operating life.

Tight-fit tests
Assembly for the automobile industry usually takes place on automated systems. During the qualification phase with the manufacturer the optimal tight fits are determined and then set for future production. To guarantee constantly high quality and adequate processability, core and sheath tight fits are tested during the manufacturing process. Moreover, the testing of tight fits on every cable drum takes place within the scope of the final inspection.

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Resistance
Continuous operating temperatures (3,000h)
Code1 Material according to DIN EN ISO 1043 and 18064
PVC PE

Temperature range in C

Thermoplastics Y 2Y 02Y 4Y 5Y 51Y 52Y 6Y 7Y 9Y 09Y

(former YW)

Polyvinyl chloride Polyethylene

-40 -50 -40 -40 -190 -190

+115 +85 +80 +100 +260 +260 +225 +200 +175

Cell-PE Polyethylene, foamed PA PTFE PFA Polyamide Polytetrafluoroethylene, modified Perfluoroalkoxy copolymer

PFA-LT Tetrafluoroethylene/Perfluoromethylvinylether copolymer -100 FEP ETFE PP Tetrafluoroethylene/Hexafluoropropylene copolymer -100 Ethylene tetrafluoroethylene copolymer Polypropylene -80 -40 -40 +125 +105

Cell-PP Polypropylene, foamed

Thermoplastic elastomers 11Y 11Y 13Y 13Y 31Y 34Y 91Y

(former 31Y) (former 32Y)

TPU TPU TPE-E

Polyurethane (PUR) Polyurethane (HT-PUR) Polyester elastomer

-50 -40 -50 -40 -65 -40 -40

+125 +150 +125 +165 +125 +150 +125

TPC-ES Thermoplastic HT Copolyester TPS PPS TPV Styrene block copolymer Polyphenylene sulphide alloy Thermoplastic polyolefin elastomer

Cross-linked materials 2G 3G 35G 4G 5G 53G 41X

1

SIR EPR AEM

Silicone rubber Ethylene propylene rubber Ethylene methylacrylate terpolymer

-70 -65 -40 -40 -40 -30 -40 -40 +100 +125 +150 +125 +120 +150 +140

+200

EVM (EVA) Ethylene vinyl acetate CR PE-C Chloroprene rubber Polyethylene, chlorinated

VTPE-O KROTHERM Flex 10 PE-X Polyethylene, cross-linked

Material Code acc. to DIN 76722

2X

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Material properties according to ISO 6722

Abrasion Flame resistance
+ * 0* ++ ++ ++ ++ ++ *

Fuel

Oil

Weather

+ + ++ 0 + + + ++ +

+ 0 0 + ++ ++ ++ ++ ++ + 0

+ 0 0 ++ ++ ++ ++ ++ ++ + 0

+ 0 0 + ++ ++ ++ ++ ++ 0 0

++ ++ ++ + 0 + +

0* 0 0* + * + *

+ + + + + + 0

++ ++ ++ ++ + + 0

++ 0 + + + ++ +

0 0 + 0 ++ + + +

0* * ++ 0* + + + +

0 0 ++ + + + + +

0 0 ++ + + + + +

++ + ++ + ++ ++ ++ 0 * Flame resistant adjustment possible

+ + excellent + O good conditionally good moderate

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Kromberg & Schubert GmbH Cable & Wire Wiegenkamp 21 46414 Rhede Germany Phone: 0049 - (0)2872 804 - 0 Fax: 0049 - (0)2872 804 - 190 E-mail: KSRH@kroschu.com www.Kroschu-Cable.de

represented corporate group Kromberg & Schubert. You will find further information on the internet at www.Kromberg-Schubert.com . In addition to the KROCAR line of vehicle cables presented here, we will also gladly inform you about our special cable programme. Please request the corresponding brochure.

Technical details subject to change without notice. GB 05 09/10

Kromberg & Schubert Cable & Wire is part of the globally