Delphi’s Interconnect System for Hybrids

Delphi has developed a unique interconnect system for hybrids. The following are the major components in their system.

The Power Pack 2000 3-way right-angle with mating header is designed for very high current applications. The connection system design features the right-angle mating capability of the Power Pack 2000 terminal system. The panel-mount header is easily applied to the high-current module case. Typical applications include inverter connections and high-voltage battery connections.

Delphi’s Contactor Electrical Center provides the main power input/output of the battery pack. Features include contactors, current sensing, and fusing for load protection.

 


Delphi’s Battery Service Disconnect provides a manual disconnect of the entire high-voltage system, allowing repair/service to the hybrid system. The high-voltage system is disabled by pulling the service plug from the battery pack. The service disconnect uses the Power Pack 2000 terminal family.

This high-voltage wiring harness with shielded tubing routes the high-voltage cables under the vehicle. The tube provides environmental protection, while offering shielding for the wiring system. Delphi can custom bend the tubing, per customer specifications, to effectively route the wiring harnesses in the harsh environment found under the vehicle.

The GT 630 two-way shielded connection system is an under-hood sealed connection system with panel-mount header and mating female harness connector. Typical applications include AC compressors, steering pumps, and oil pumps. The connection design features include terminal cavity isolation, internal and sealed shielding, and lever assist for ease of assembly.