Power distribution units (PDUs)
The core of machine electrical systems
Every electrical machine requires at least one Power Distribution Unit (PDU) — sometimes more. As the name implies, the PDU serves as the central hub connecting the machine’s electrical system. At higher powers, every cable is point-to-point and must be properly terminated. Splices are not an option.
Beyond providing connection, the PDU is the foundation of a machine’s electrical architecture and electrical integrity, ensuring performance and safety in tough conditions. Our high-voltage, high-current PDUs for off-highway machines and special vehicles are designed to meet the following demands.
- Minimal envelope: Tight space constraints require innovative design to safely isolate high-voltage components
- Harsh Environments: PDUs are protected against water ingress, impact, vibrations, and altitude changes
- Thermal Management: Effective heat management is crucial, especially in enclosed spaces where high-current components generate significant heat.
Short lead times for prototype and production
The PDU design cannot be finalized until late in the machine development process, yet it is one of the first components to be installed. This makes PDU lead time a critical factor for project success, and we can supply within 10 weeks.
The materials and design choices for prototypes are optimized for rapid delivery without compromising safety or quality.
As a machine design stabilises and we move towards pre-series and series production, we have defined technology volume breaks that enable machine BOM cost optimisation.
Do I need an “off-the-shelf” or a custom designed PDU
For smaller, low-power machines with simple operation, off-the-shelf PDUs are feasible. Lower currents and voltages reduce component size and cost, so if peak machine power demand is less than 75 kW, then inquire about our standard designs.
However, as power requirements and operational complexity increase, a standardized approach becomes impractical. A universal PDU capable of meeting all customer requirements would likely be oversized and prohibitively expensive.
- The costs of components such as connectors, busbars, and contacts rise exponentially with power, making it uneconomical to incorporate components that are not strictly required.
- Large cables carrying hundreds of amps further complicate matters, as they often have minimum bend radii exceeding 0.3 m (1 foot). The direction of cable entry into a PDU can thus dictate connector placement, which in turn has a knock-on impact on the internal layout of the unit.
Technical characteristics
Optional features
- Circuit switching: contactors, control units and software to depending on the operating modes of the machine
- Safety Interlock Systems: Ensuring the machine only operates when all connectors are correctly plugged in
- Pre-Charge Circuits: To reduce the voltage differential when closing a contactor, minimizing the risk of arcing
- Discharge Circuits: To safely discharge residual voltages
Electrical capabilities
- Up to 400 KW
- Up to 800 V DC
- Up to 500 A
Enclosure
- First samples – standard enclosure or milled from solid
- Pre-series and volume production – Standard enclosures or pressed steel
All enclosures are mechanically protected against impact, vibration and ingress protection (IP67) and fitted with a Gore anti-condensation ventilation membrane.
Electrical features
- Busbar technology -Prototype and pre-series
- Power PCB – volume production
- Fuses
- Choice of robust, sealed connector families available to facilitate machine assembly
- ECM features
Functional safety
- ISO 26262 and IEC 61508 and related sector standards
- ASIL B as standard. Up to ASIL D optional