Electric vehicle high voltage cable solution requirements

International crude oil prices continue to rise, the whole society is more concerned about environmental degradation and global warming, coupled with the preferential taxation and policy support of various governments, the market share of alternative energy, especially electric vehicles, continues to grow worldwide.

Whether it is a pure electric vehicle, a hybrid vehicle or a fuel cell vehicle. Their common feature is the use of driving voltages up to 600V or higher, and when it comes to wiring, they all share the same basic requirement of safely transmitting high currents and voltages under EMI (Electromagnetic Interference) protection systems.

High-voltage cables are carriers for power and electrical energy transmission by dry-connecting high-voltage batteries, inverters, air-conditioning compressors, three-phase generators and motors. With the advancement of technology, new technical requirements have been placed on issues such as flexibility, shielding, safety, size, etc. of high-voltage cables for electric vehicles, as these affect high-current and high-voltage component wiring.

The specific requirements for electric vehicle high-voltage cable solutions are as follows.

1. The basic difference between voltage and conventional automobile cables is that the structure needs to be designed with a rated voltage of 600V, while if used in commercial vehicles and buses, the rated voltage can be as high as 1000V. Cables currently used in vehicles powered by internal combustion engines are designed to be rated at 60V. When the system generates power (P=U*I) unchanged, due to the use of lower current, high voltage can reduce the power loss in the transmission system

2. Since the cables connect the battery, the inverter and the motor, the high voltage cables need to transmit high current. Depending on the system component power requirements, the current can reach 250A to 450A. Such high currents are hard to find on conventionally driven vehicles.

3. Temperature high current transfer results in high power consumption and component heating. Therefore high voltage cables are designed to withstand higher temperatures. At present, it can be seen that there is a further increase in the temperature requirements. In contrast, current vehicles generally use cables rated for a temperature of 105°C, as long as the cables are not used in the engine compartment or other high temperature resistant areas. Electric vehicle high-voltage cables are usually higher than this temperature, such as 125°C or 150°C. If the routing in the electric vehicle is unfavorable, the OEM will even put forward higher requirements for high temperature resistance. Such as near the exhaust pipe, in front of the motor, on the back of the battery, etc.

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