Vigh-voltage Distributor

An electrified journey begins with a fully charged battery and the safe distribution of supply voltage and power in the vehicle electrical system. This truly exciting customer project involved developing system components that ensure the safe monitoring of the high-voltage charging voltage and the internal vehicle electrical system for the other consumer modules in the vehicle – the high-voltage distributor.
The high-voltage distributor, or HVV for short, forms the first interface in the vehicle after the charging station and will be used in two versions in public transport, specifically in the 12-metre solo bus and the 18-metre articulated bus. The plan is to have over 800V on-board voltage and up to 250A charging current in the first stage of expansion. The development covered hardware, software and mechanics, with a focus on functional safety: thanks to its 100% passive cooling, the HVV can be operated independently of the vehicle cooling system, thus offering greater flexibility in vehicle design.
Its placement in the vehicle also serves this purpose: the current version of the HVV is mounted directly on the vehicle roof. This frees up as much space as possible and ensures a high level of comfort for passengers. In order to harmonise function and comfort, we ensured that the HVV’s housing was absolutely robust and waterproof, providing optimum protection against environmental influences.
To meet the safety requirements, the diagnostic functionality was implemented independently on a hardware basis in parallel with the software monitoring, which enabled efficient implementation of the system design. Parallel to development, requirements management was maintained at the customer’s site and test progress was logged.
For developers, the greatest recognition is seeing customers satisfied and their own concept become reality. In this sense, we are proud that, thanks to a hands-on mentality and a high degree of parallelised work, the first vehicles with the high-voltage distributors we developed were successfully approved and delivered to companies in a very short time.