In the automotive industry, cables are usually designed for a service life of 3000 h at the specified temperature level, a value that is usually used for long-term aging tests in recognized cable standards (e.g. ISO 6722, ISO 14572). Customer-specific requirements in high-voltage applications may exceed 3000 h and even reach up to 12000 h cumulative operating time at the specified temperature.
In terms of cable shielding effectiveness, high-voltage cables are divided into shielded and unshielded products, distinguishing them from coaxial cables that transmit data but need to prevent or reduce the high-frequency radiation generated by switching power supplies in the system from being induced through the cable to surrounding components.
Unlike fuel-driven vehicles, three-phase AC power to control the motor of an electric vehicle becomes necessary. The sinusoidal voltage carrying energy is equivalent to square wave pulse signals of different frequencies. Since the high frequency pulses have steep edges, they generate harmonics with high energy emission into the surrounding area.
EMI problems can be completely solved by using appropriate shielding methods. In some cases to meet the different requirements of the shielding effect need to use a combination of different shielding types.
Regarding the issue of cable flexibility, the challenge faced by the development of hybrid vehicles in many cases is that the existing series platforms were originally designed to load only the gasoline engine and its components in the space incorporated more electrical components. Space limitations can be expected, even without considering wiring.
In addition, space is required for routing cables and connectors through. The usual consequence is the resulting tight bend radius. Due to the inherent design of conventional cables, high bending forces are difficult to overcome. To solve this problem, high flexibility in high-voltage cables is essential. Only a more flexible design can be easily achieved by routing through the vehicle.