Rosenberger introduces the HVR280, a new generation of automotive high-voltage connectors, supporting up to 1200V DC and compatible with all specifications of high-voltage wiring harnesses.
Rosenberger, a global leader in automotive connectivity systems, has released its HVR®280 fully shielded automotive high-voltage connector series. As an iteration of the previous HVR270, the new product boasts a maximum withstand voltage of 1200V DC and a continuous current carrying capacity of 310A. Designed specifically for high-voltage wiring harness assemblies and Tier 1 suppliers in automotive systems, it is compatible with 35/50/70mm² copper and aluminum core high-voltage wiring harnesses, fully matching current and future 800V, 1000V, and 1200V automotive high-voltage electrical platforms.
With the continuous upgrading of fast charging power in new energy vehicles and the widespread adoption of high-power power systems in hydrogen fuel cell commercial vehicles, high-voltage wiring harnesses in vehicles face multiple stringent requirements regarding connector voltage, current carrying capacity, assembly efficiency, and lightweight design. The complexity of traditional high-voltage connector components, cumbersome wiring harness assembly processes, and the incompatibility between high and low voltage platforms have long constrained the mass production efficiency of wiring harness factories and the integration capabilities of vehicle systems. The HVR280 series, now in operation, adopts a core design philosophy of "high performance + simplified mass production," simultaneously addressing two major pain points: wiring harness manufacturing and vehicle wiring.
I. Robust Electrical Performance, Compatible with All Types of High-Voltage Wiring Harnesses
In terms of core electrical specifications, the HVR280 achieves a generational performance upgrade:
Rated operating voltage up to 1200V DC, providing ample voltage withstand redundancy to cover all high-voltage wiring harness scenarios, including 800V fast-charging passenger vehicles, 1000V/1200V hydrogen fuel cell heavy trucks, and energy storage vehicle-mounted units;
Sustainably withstands 310A current at 85℃ ambient temperature, with a short-term peak current of up to 653A, handling the instantaneous current surges during rapid vehicle acceleration and high-power fast charging;
Natively supports 35mm², 50mm², and 70mm² single-core high-voltage cables, and can stably crimp copper conductor and lightweight aluminum conductor wiring harnesses, adapting to various assemblies such as battery main wiring harnesses, PDU to inverter wiring harnesses, and on-board charger high-voltage wiring harnesses;
Integrated fully shielded structure effectively suppresses EMI electromagnetic interference generated by high-voltage wiring harness operation, allowing for placement in confined wiring areas around autonomous driving control zones without affecting the stable transmission of vehicle signal harnesses.
II. Optimized for Automated Wiring Harness Production Lines, Significantly Reducing Costs and Increasing Efficiency
Targeting the mass production needs of wiring harness assembly factories, the HVR280 features a simplified structural design, becoming the benchmark solution for automated wiring harness production lines:
Both straight and 90° elbow wiring harness plugs share the same 4-hole flange socket, requiring wiring harness manufacturers to maintain only one set of tooling molds, halving the number of material categories and significantly reducing inventory and mold-making costs;
Connector components are streamlined by 30%, eliminating redundant locking accessories. Automatic crimping, shielding, and locking processes can be integrated, shortening assembly time;
Equipped with a lever locking + CPA dual confirmation mechanism, the wiring harness plug automatically locks to prevent loosening after proper assembly. The visual confirmation structure of CPA eliminates vehicle safety hazards caused by loose connections or improper assembly;
Optional integration of HVIL high-voltage interlock circuit allows the wiring harness assembly to meet global mandatory high-voltage safety standards for vehicles from the factory, eliminating the need for additional accessories.
Meanwhile, the product adopts a compact and lightweight housing, reducing the overall weight of the high-voltage wiring harness assembly, effectively freeing up chassis and engine compartment wiring installation space, and optimizing the vehicle's weight distribution. The entire series complies with RoHS environmental standards, and relying on Rosenberger's global "local-for-local" production system, wiring harness factories both domestically and internationally can be sourced locally, shortening delivery cycles.
III. Stringent Automotive-Grade Reliability, Adaptable to Complex Road Conditions The HVR280 has passed a full set of automotive environmental reliability tests, adapting to the bumpy road conditions of commercial vehicles and the wide temperature range operating environment of passenger vehicles: meeting the high-level vibration standard of DIN/TS 70214, with no issues of loose needles or excessive temperature rise under long-term vibration; the operating temperature range covers -40℃ to 125℃, and it has fully passed multiple rounds of high and low temperature cycling, damp heat, and salt spray tests, ensuring stable connection of the high-voltage wiring harness throughout its entire life cycle. Our products are widely compatible with four major vehicle wiring harness application scenarios:
800V high-voltage fast-charging pure electric vehicles: battery pack - PDU, PDU - electric drive inverter high-voltage main wiring harness;
Hydrogen-powered and pure electric heavy-duty trucks: 1000V/1200V high-power power transmission wiring harness;
Plug-in hybrid and range-extended electric vehicles: high-power DC high-voltage wiring harness;
On-board energy storage and high-power OBC charger high-voltage wiring harness assemblies.
In an interview with the company, the Global Product Director of Rosenberger Electric Drive stated, “Currently, high-voltage wiring harness manufacturers and OEMs face two major challenges simultaneously – the performance requirements for higher voltage and power, and the manufacturing requirements for cost reduction and automated mass production. The core of the HVR280's development is to break the inherent industry contradiction that ‘high performance inevitably leads to complex and difficult assembly.’ While improving the ultra-high load-bearing capacity to 1200V, we have simplified the entire process from the wiring harness assembly end, helping wiring harness companies improve production line utilization, reduce the cost per unit of the assembly, and provide a standardized solution for the upgrading of wiring harnesses for high-voltage platform vehicles in the next five years.” Industry Value Summary Industry analysts point out that with the continuous increase in the penetration rate of 800V vehicles in China and the accelerated industrialization of hydrogen fuel cell commercial vehicles, the market size of high-voltage wiring harnesses above 1000V will experience rapid growth. The deployment of the HVR280 fills the product gap in the "1200V high-power + automated mass production of wiring harnesses" track for high-voltage connectors. It provides wiring harness manufacturers and OEMs with a standardized high-voltage connection solution that is both forward-looking and economical, accelerating the domestic substitution of high-voltage wiring harnesses and the popularization of high-voltage platform vehicles.
About Rosenberger: Rosenberger is a leading global R&D and manufacturing company of RF, high-voltage, and high-speed automotive connection systems. With years of experience in the high-voltage wiring harness sector for new energy vehicles, its HVR fully shielded high-voltage connector series is a core component for major global automakers and leading Tier 1 suppliers of wiring harnesses. The company continuously iterates its connector technology to meet the needs of high-voltage, high-speed domain control, and on-board charging wiring harnesses for vehicles, providing a complete set of reliable interconnection solutions for electrification and intelligent mobility.
