Characterization and optimization of high-voltage cables for electric vehicles

China [CN]

Perfectly complex designs and the use of high quality materials will result in expensive cable costs. The test effects on the cable can be optimized in terms of cross section, temperature requirements, flexibility and shielding effect. Of course, weight and cost savings can be highlighted and other details can be accessed for More.

The combination of the theoretical basis and the experience gained in reality allows the initial identification, selection and obtaining of optimized high-voltage cables for the application.

 1. Variation in cable cross-sectional area and temperature rating.

The selection of cables is mostly based on the ambient temperature and the indicators of the transmitted current. In this regard, the most important characteristics are the "cable cross-section" and the "thermal class of the material used in the cable".

The voltage drop of the conductor is converted into thermal energy to heat the conductor of the high-voltage cable. This heat can be partially transferred to the environment, making the conductor run cooler. Lower temperature gradients can transfer less heat. Continuous load currents in cables can lead to withstand the highest rated temperatures. This temperature can cause aging of the materials used.

2, the optimization of cable flexibility

The available space for cabling the vehicle deserves careful consideration. The need for tight bend radii in only one specific area of the vehicle can lead to higher overall cable flexibility requirements. If it is possible to make small changes in the overall design, it makes sense to avoid the problem of tight bends.

It is not necessary for the cable to have the highest flexibility. The exact definition of the bending force, combined with the construction and the corresponding test equipment, allows the cable designer to create the most suitable design for the application. Especially for larger cross-sectional cables, replacing highly flexible designs with more flexible or conventional structural designs will significantly reduce costs. Specific specifications can be developed as needed.

3、Optimization of shielding effect

A defined shielding effect in a certain frequency range is essential for the development of cables. More details on shielded versus unshielded cables can be found at More.

Finally, the high-voltage wiring harnesses of vehicles still have a long way to go compared to conventional wiring systems. Specific specification requirements should be planned by technical expertise, allowing for more cable solutions and the development of high-voltage equipment more suitable for the application.

For more EV cable information : https://www.omgevcable.com