Optimum design of electric vehicle high-voltage cable structure
China [CN] There is still a long way to go in the wiring of high-voltage cables for electric vehicles. The high-voltage cables after the structural optimization design can improve the overall performance. Now it is mainly explained from three aspects: optimization of cross-sectional area and temperature level, optimization of flexibility and optimization of shielding effect.
1. Optimization of cross-sectional area and temperature class
There are also certain skills in the selection of cable specifications. Excessive conductor size may lead to increased cost and weight. High-voltage cables used at higher load currents and ambient temperatures also have certain requirements for large-section and high-temperature resistant materials.
Determining the relationship between current and load ambient temperature should take into account the real drive periodic dynamic current peaks, allowing for a reasonable definition and worst-case load current and peak current.
Generally, large-section high-voltage cables have large inertia in terms of temperature changes, so the current peaks of vehicle acceleration or deceleration will not cause a large conductor temperature effect.
Allowing for occasional short-term temperature peaks even in excess of the cable temperature classes defined above, the ability of a high voltage cable to handle these peaks is usually defined by thermal overload performance.Consequently, the cable does not need to be designed for a higher operating temperature class, and there is no need to use a cable that exceeds the specified operating temperature.
A combination of resident load current and single pulse or series of pulses together with various parameters such as ambient temperature can be taken into account.
2. Optimization of flexibility
The car wiring space is small, and the tight bending radius only in a specific area of the vehicle will lead to an increase in the flexibility of the overall cable.For larger cross-section cables, replacing the highly flexible design with a more flexible or conventional structural design can significantly reduce costs.
3. Optimization of shielding effect
Good shielding can prevent or reduce external electromagnetic interference.The shielding effect without frequency information is not very useful, which may lead to solutions with excessive size and the use of expensive combined shielding, which is no longer a technical point of view.necessary.
For more EV high-voltage cable design requirements and product information, please visit OMG's official website:
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