Setting a new standard for EMC cable glands in e-mobility applications
AGRO’s EVolution EMC® cable gland
First EMC cable gland with disconnectable ("pluggable") shield contact solution for electric vehicles / Supports more cost-efficient and reliable manufacturing / With an innovative design that simplifies maintenance and repair work in a new way / Reliable shield connection thanks to use of AXI PRESS® tool / Meets all e-mobility requirements / High-performance / Lead-free brass
Hunzenschwil, Switzerland. The cable gland specialist AGRO has now introduced a completely new type of cable gland to meet the special needs of high-voltage vehicle electrical systems in electromobility applications. The compact EVolution EMC® cable gland, the first with a disconnectable ("pluggable") shield contact solution, is used for cable feedthroughs in hybrid or fully electric vehicles. According to the manufacturer, it not only meets the most demanding requirements in terms of electromagnetic compatibility (EMC), but is also very quick to install and proves to be robust, effective, durable and reliable in all operating situations.
Quick installation
Thanks to its axial crimping technology (patent pending), the new EMC shield contact solution enables vehicle manufacturing processes to be made simpler, less costly and more reliable, because it allows cable harnesses to be pre-assembled independent of the main manufacturing cycle. This not only enables the work to be carried out more ergonomically, but also reduces installation times on the vehicle. During installation, the cable lug is simply passed through the cable gland and the cable pushed through as far as the contact sleeve allows; the sealing insert is pushed along the cable into position; and the pressure nut is tightened to the limit. Although this does not even require a torque wrench, IP-level sealing is ensured. In this way, vibration-related uncertainties relating to the pressure nuts, which in the past had to be torqued onto rubber sealing inserts, are avoided in operation.
Designed for easy maintenance – a first!
The new technology also enables future maintenance and repair work to be carried out quickly, easily and precisely, without any loss of performance. For example, a special slit in its silicone material enables the sealing insert to be easily replaced without disconnecting the inner conductor from the system. And repeated “plugging in” of the shield contact does not damage the cable shield.
Able to meet all requirements
For crimping the contact sleeve, the battery-operated AXI PRESS® tool is used. This hand-held device is supplied by AGRO with the required fittings, and ensures a quick and reliable shield connection. The cable shield is then well protected from wear and damage, even in the most demanding operating conditions.
The new EVolution EMC® system is specially designed for the types of high-voltage cables used in electric vehicles, with braided copper shields and with cross-sections of between 16 and 120 mm². It is the only EMC cable gland on the market that meets all the requirements of the electromobility sector for the most common high-voltage conductors and power classes. In this wide application area, high currents often occur in the motor supply lines, which, due to the high switching frequencies from DC/DC converters and AC transformers, further load the vehicle electrical system with high-frequency interference. Therefore, the durability and longevity of the cable glands are very significant in relation to the vehicles’ operational reliability.
Wide range of applications
These EMC cable glands are primarily used in commercial vehicles and in construction and agricultural machinery, in connection with power distributors, air compressors, coolers, high-voltage braking resistors, air conditioning compressors, steering pumps, auxiliary drives, mains chargers, high-voltage and DC/DC inverters, and fuel cells. EVolution EMC® ensures sealing in accordance with protection class IP 68 (up to 5 bar) or IP 6K9K over the entire temperature range, and is available with short or long connection threads in sizes M20 to M32. The compact cable glands are made of coated lead-free brass. Their operating temperature range is between -40°C and +140°C. The current carrying capacity of the shield contacts is between 115 A for M20x1.5 and 195 A for M32x1.5. Available accessories include protective caps for internal electronics housings, EMC locknuts for mounting on thin or painted metal sheets, and anti-kink sleeves to prevent kinking of cables.
With this new generation, the Swiss manufacturer, which has long been known for the quality of its products, has redefined what can be expected with respect to performance and application limits of EMC cable glands. In doing so, it now offers new solutions for vehicle manufacturers and cable assembly companies, covering the entire range of e-mobility requirements, that are not just simple, efficient and cost-saving, but are also reliable and durable in operation. Furthermore, they enable – as a first – the time and cost associated with future maintenance and repair work to be substantially reduced.
AGRO electrical installation systems
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