Structural design of high-voltage cables for electric vehicles

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Structural design of high-voltage cables for electric vehicles
Posting date : Nov 14, 2022
Free Member Scince Oct 23, 2021
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Standard products and very specific requirements are difficult to define. The purpose of this paper is to solve the basic design ideas and overcome the challenges described above by applying advanced high-voltage cable structure principles.

Conductor design: The flexibility of high-voltage cables is mostly determined by the conductor design. This is why high-voltage cables use special conductors with a large number of very small diameter monowires. A certain number of monowires shall be bundled and twisted first, and then concentric twisted to form a flexible conductor required for high-voltage cables.

Another advantage of the larger number is better bending resistance. Shorten strand pitch can also improve the bending life of high-voltage cables.

Insulation material: the selection of insulation material is mainly based on heat resistance requirements and mechanical strength. Compared with standard battery cables, soft materials can be reasonably selected to keep the specially designed stranded conductors flexible.

Cabling: When the cable is multi-core, it is usually necessary to twist the core. In order to compensate for the deformation caused by the twisted high-voltage cable core, the so-called untwisting special equipment is required. In this process, the pay off reel equipped with the special strander rotates in the opposite direction to the stranding direction. This is necessary to prevent cable deformation and tension.

According to the structure of the cable, filling is usually used to ensure a high concentricity of the shielded cable and finally obtain a satisfactory high-voltage cable. The use of tape wrapping in the twisted cable core can maintain the flexibility of the cable.

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