EV high-voltage cable structure design ideas
China [CN] The structure of electric vehicle high-voltage cables is generally composed of four parts: conductor, insulation, shielding, and sheath. Of course, if there is no shielding, it is the remaining three parts. Now we mainly talk about the design ideas of four parts.
1. Conductor design
High-voltage cables are used for wiring inside automobiles, and they need to have good flexibility. Of course, flexibility is largely related to conductor design, which is why high-voltage cables need to use a large number of thin conductors to be bundled first, and then concentric. reason. In addition, the conductor designed in this way has better bending resistance, shortens the strand pitch, and can also improve the bending life of the high-voltage cable.
2. Insulation material
The choice of insulating material needs to consider heat resistance and mechanical strength.Compared with standard battery cables, it is generally necessary to select materials with better softness and use special designs to ensure the flexibility of conductors.
3. Shielding design
In order to meet EMC (Electromagnetic Compatibility) requirements, it is necessary to use multiple copper wires to form a braided shield.Tinned copper wire makes it more resistant to environmental influences such as oxidation.Using thin copper wire can maintain the flexibility of the design, and the shield needs to have a coverage rate of more than 90% to overcome the EMI problem.
Of course, in addition to the braided shield, the shield can also be wrapped with a layer of non-woven fabric to ensure easy peeling of the sheath during assembly.
4. Sheath design
Like the insulation of the wire core, the jacket material has thermal and mechanical requirements.Due to the harsh environment inside the car, it is necessary to design materials that can meet the properties of liquid resistance and wear resistance.
If there are special requirements, such as in order to overcome the wear of the installation vehicle environment, the sheath material also needs to have good wear resistance.
In general, there are also relevant requirements for the color of the sheath material, usually bright orange is required to warn of high pressure.
For more ev high-voltage cable and ev charging cables,please visit the official website of OMG: https://www.omgevcable.com
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