Requirements for high-voltage cables of electric vehicles

Innovative electric vehicle design poses new challenges to high-voltage cables and system components, which cannot fully adopt existing solutions. The specific requirements are analyzed as follows.

For voltage: the basic difference between the cable and conventional automobile cable is that the structure needs to be designed according to the rated voltage of 600 V. If it is used on commercial vehicles and buses, the rated voltage can be up to 1000 V. By contrast, even higher. At present, the cables used in cars driven by internal combustion engines are designed to have a rated voltage of 60 V.

Power generated by the system at (P=U × 1) Under the same condition, due to the use of lower current, high voltage can reduce the power loss in the transmission system (PLOSS=I2 × R)。

For rated current: as the cable connects the battery, inverter and motor, the high-voltage cable needs to transmit high current. According to the power requirements of the system components, the current can reach 250A to 450A. Such a high current is difficult to find on vehicles with conventional drive.

Temperature resistance: High current transmission 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 trend to further increase the temperature requirements.

In contrast, the rated temperature of cables used by current vehicles is usually 105 ℃, as long as the cables are not used in the engine compartment or other high temperature resistant areas. High voltage cables of electric vehicles are usually higher than this temperature, such as 125 ℃ or 150 ℃.

If the routing of electric vehicles is unfavorable, the OEMs will even put forward higher requirements for high temperature resistance. For example, near the exhaust pipe, in front of the motor, on the back of the battery, etc.

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