Cables & Lines Special Line for E-Mobility Test Benches

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HELUKABEL GmbH

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The American company Anderson Electric Controls (AEC) equips, among other things, test benches for electric vehicles and drive batteries. For a project, the specialist required an individual connection line, as the complex customer requirements could not be met with standard products. Therefore, AEC approached Helukabel with their request.

Electromobility is on the rise—and with giant strides: The number of global new registrations of electric cars has increased from around 128,000 in 2012 to around 17 million in 2024. This is not only due to people's heightened environmental awareness or various funding and subsidy programs, but also to continuous advancements on the technical side: E-cars offer ever greater range, the charging infrastructure is becoming better across the board, and charging times are shorter. This makes e-mobility increasingly attractive for drivers.

The heart of every electric vehicle is the battery: It determines how far the user can go on a single charge and how much time they need to plan for charging. To achieve optimal performance, battery manufacturers are continuously working to make batteries more compact and lighter while also stronger and more efficient. Automotive companies are also investing significant effort in research and development to better align the vehicle and battery.

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From Tunnel Boring Machines to E-Mobility

"Special test benches are used for this, allowing a wide variety of functions and scenarios to be tested under realistic conditions," explains Ron Hansen, managing director of Anderson Electric Controls, Inc. (AEC). The company, based in Kent, Washington, USA, specializes, among other things, in equipping such test benches for original equipment manufacturers in the automotive industry. AEC's roots lie in control technology for tunnel boring machines, but over time, its portfolio has been expanded to include several other business areas.

"For example, we develop and supply cycler and emulation systems for batteries for our customers," explains Steven Hansen, Technical Director at AEC. "These are electrical devices that simulate the behavior of a real vehicle battery on a test bench." Capacity, state of charge, or the structure of the battery cells can be flexibly parameterized—meaning the user can replicate different battery types and operating environments. "Automotive manufacturers use these systems to test and optimize the behavior of drive batteries and onboard power systems in their vehicles," reports Ron Hansen. "They can also use them to determine the expected performance of vehicle batteries that have not yet been installed, as well as to identify charging, capacity, efficiency, or safety issues."

High Voltage Resistance Required

AEC customizes the equipment of the test systems to meet the specific requirements of its customers—as in the case of an international automobile manufacturer that needed a new test bench for electric vehicles for a plant in the USA. Very specific connection lines are used to connect the drive batteries to the cycler.

A challenge here was the high voltages of 2 kV and more that are applied to the lines during the test procedure. Additionally required were UL approval, a so-called TC-ER certification for open installation, and low inductance to avoid EMC interference.

Matt Tavares, Mechanical Engineer at AEC

It quickly became clear to those responsible at AEC: these complex requirements could not be met with a standard cable. In their search for a suitable solution, they soon came across Helukabel: the internationally leading provider of electrical connectivity technology is also represented in the USA with a subsidiary. "In several discussions, we were convinced that we had found the right partner for this project with Helukabel," recalls Tavares.

Tailor-Made And on Time

After all details were clarified, the Helukabel designers set about designing a connection cable for the planned battery test bench. "At Helukabel, we have decades of experience in developing custom solutions and dedicated expert teams for this purpose," says David Newton, the responsible Regional Sales Manager. "Realizing the desired product features was therefore no problem for us."

The cable specifically developed for AEC impresses, among other things, with its excellent resistance to oil and moisture. "In addition, it has a TC-ER approval—this means it can be installed without a conduit or closed cable channel," adds Newton. "And, of course, we took care of the necessary approval by Underwriter's Laboratory (UL), the leading certification organization in the USA."

Another advantage for the manufacturer was that the desired cable could be provided within the delivery timeframe specified by AEC. "With other manufacturers, the lead times were simply too long, which would have meant making our customers wait," says Tavares. "Helukabel delivered a solution that met all our expectations—and did so quickly, competently, and reliably."

The door for further collaboration with Anderson Electric Controls is more than just open, reveals Managing Director Ron Hansen. "The next order has already been placed, and further joint projects are already in planning."

Ron Hansen, President of Anderson Electric Controls, Inc. (AEC)

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