P_KroCar_GB

KROCAR®

Automotive Cables

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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.

The right cable as part of your system solution

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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 automo-

tive applications for several years.

Realised solutions

safety

multimedia

drive/chassis

utility vehicles

hybrid vehicles

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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.

Safety

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)

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Electric parking brake

For decades, extremely flexible and notch-resistant materials have proved success-

ful 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 strip-

ping 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 insula-

tion 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.

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As a result of the increasingly more powerful engines and gearboxes, the temperature require-

ments 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 respec-

tive requirement in temperature and media resistance.

Drive / Chassis

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

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.

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.

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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 develop-

ment 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.

Alternative drives

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), depend-

ing 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.

Realised solutions

power cables up to

200 °C / 3,000 h

control cables up to

200 °C / 3,000 h

Combustionengine

Micro Hybrid Mild Hybrid Full Hybrid Plug-in Hybrid

Combustionengine

Combustion engine

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Start / Stop

Increasing level of electric mobility

Parallel drive

Fossil fuels

Storage capacitor

Fossil fuels

Fossil fuels

Electricmotor

Electricmotor

Combustionengine as

range extender

Parallel drive

Fossil fuels

Storage batteries

Serial drive

Storagebatteries

Fossil fuels

Storagebatteries

Electric motor

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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 devel-

oped 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).

Multimedia

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 temper-

atures 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 cameras CAN-Bus car and mobile phones EMOST

Ethernet FlexRay™ GVIF/USB LVDS/CD players

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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 ful-

fils the safety-related demands in a car. With a data

rate of up to 10 Mbit/s, FlexRay™ aims at applica-

tions 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.

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Utility vehicles must have a particularly high availability in an extraordinarily cost-sensitive environ-

ment. 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.

Utility vehicles

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 influ-

ences, such as various oils, lubricants and cleaning fluids, are particularly

high. In this context, Kroschu cables with the cross-linked sheathing mate-

rial 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 combina-

tions 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 AdBlue connection between tractor engine and trailer

150 °C / 3,000 h and 175 °C / 15,000 h BUS cabling lighting system cabling

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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.

Test engineering

Material tests

Kromberg & Schubert has an in-house testing laboratory and thus create

optimal prerequisites regarding the new and further development of mate-

rials and cables.

Thermal tests

Kromberg & Schubert has climatic chambers for the simulation of environ-

mental 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 atten-

uation 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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1 Material Code acc. to DIN 76722

Continuous operating temperatures (3,000h)

Code1 Material according to DIN EN ISO 1043 and 18064 Temperature range in °C

Thermoplastics

Y PVC Polyvinyl chloride

2Y PE Polyethylene

02Y Cell-PE Polyethylene, foamed

4Y PA Polyamide

5Y PTFE Polytetrafluoroethylene, modified

51Y PFA Perfluoroalkoxy copolymer

52Y PFA-LT Tetrafluoroethylene/Perfluoromethylvinylether copolymer

6Y FEP Tetrafluoroethylene/Hexafluoropropylene copolymer

7Y ETFE Ethylene tetrafluoroethylene copolymer

9Y PP Polypropylene

09Y Cell-PP Polypropylene, foamed

Thermoplastic elastomers

11Y TPU Polyurethane (PUR)

11Y TPU Polyurethane (HT-PUR)

13Y TPE-E Polyester elastomer

13Y TPC-ES Thermoplastic HT Copolyester

31Y TPS Styrene block copolymer

34Y PPS Polyphenylene sulphide alloy

91Y TPV Thermoplastic polyolefin elastomer

Cross-linked materials

2G SIR Silicone rubber

3G EPR Ethylene propylene rubber

35G AEM Ethylene methylacrylate terpolymer

4G EVM (EVA) Ethylene vinyl acetate

5G CR Chloroprene rubber

53G PE-C Polyethylene, chlorinated

41X VTPE-O KROTHERM® Flex 10

2X PE-X Polyethylene, cross-linked

+85-50

-50

-50

+115-40

+80-40

+100

+100

-40

-40

+140-40

+175-80

+125-65

+125-30

-40

+150-40

+125-40

+105-40

-40

+125-40

+125

+125

+125

+225

+200

-100

-100

+120-65

+260

+260

-190

-190

+165-40

+200-70

+150

+150

+150

-40

-40

(former 31Y)

(former YW)

(former 32Y)

Resistance

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+ + excellent

+ good

O conditionally good

– moderate

* Flame resistant adjustment possible

Material properties according to ISO 6722

Abrasion Flame Fuel Oil Weather resistance

+ + + + +

+ – * 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 * + + +

+ + + + + + +

+ + + + + +

+ + + + + +

+ + + + 0

Kromberg & Schubert Cable & Wire is part of the globally

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.

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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: [email protected]

www.Kroschu-Cable.de