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KROCAR®
Automotive Cables
2
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
3
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
4
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)
5
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.
6
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.
7
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
Com
bust
ion
engi
ne
Ener
gy s
tora
ge
Com
bust
ion
engi
ne
Elec
tric
mot
or /
Boos
t
Elec
tric
mot
or /
Ener
gy re
cove
ry
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
8
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
9
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.
10
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.
11
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
12
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.
13
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.
14
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
15
+ + 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.
Tech
nica
l det
ails
sub
ject
to
chan
ge w
ithou
t no
tice.
GB
05 0
9/10
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