High-voltage distribution using the example of electric commercial vehicles

The electrification of light commercial vehicles places particularly high demands on high-voltage management. Compact installation space, high power density, redundancy in the traction drive and a reliable supply to all auxiliary consumers must be combined in a central system.

The L38A-80X1 power distribution unit is responsible for the complete distribution, monitoring and protection of the electrical energy in the van. In this configuration, the PDU is designed for 800-volt systems.

The PDU impresses with its compact design with particularly small external dimensions and high performance. This means that it can be optimally integrated even in confined installation spaces. Installation is simple and practical: The PDU can be easily and safely mounted in the vehicle via a perforated plate with regard to crash or shock and vibration. A corresponding measuring module is installed for continuous monitoring of the relevant voltages and currents.

Thanks to the design in a sealed box construction in accordance with IP protection class, no additional sealing is required. Integrated measuring point openings also make it possible to manually check that the high-voltage system is voltage-free. This facilitates the safe decommissioning of the vehicle and ensures optimum ease of servicing.

A key feature is the pluggable high-voltage inputs and outputs, which enable a parallel batterymultipack connectionfor connecting up to five high-voltage batteries. A redundant energy system, which continues to run consistently even if one battery fails, has been implemented accordingly in the PDU. This increases the availability and operational safety of the vehicle.

• HV inputs with 35-70mm2 cables (maximum 300A per input)
• Optional HV inputs with 16-25mm2 cables (maximum 120A per input)
• 1x HV input (fused) with 16mm2 cables for the on-board charger (OBC)
• 1x HV input (fused, all-pole switched and voltage-monitored) with 70-95mm2 cables for the CCS DC charging inlet (up to 350kW charging power)
• 2x HV outputs (fused) with 35-70mm2 cables for drive or auxiliary drive
• 4x HV outputs (fused) with 2-5mm2 cables for small consumers (DCDC, thermal management, etc.)
• Customized fuse design (AE7 fuses, 800V, 60-800A)

Load connections: what is supplied with power via the PDU

The system in this application is designed for an all-wheel drive concept in the commercial vehicle sector, which could also be implemented in the PDU. This means that two drive units can be supplied in parallel operation. In addition, a further four consumers:

1. Front drive
2. Rear drive
3. Heat pump
4. DCDC converter
5. High-voltage heater
6. High-voltage compressor

The L38A is a powerful compact package with a weight of 12 kg in relation to the number of inputs and outputs. It is designed for modern vehicles and machines with many high-voltage components.

Note: Our PDU products can be used for a wide variety of vehicles on wheels, tracks and rails as well as for a wide variety of machines with complex requirement profiles and can be customized depending on the application. All details on the various PDUs are available on the overview page.