Overview of new energy vehicle high-voltage cable process pathways

China [CN]

Through the selection of automotive cable specifications, for most car companies or manufacturers, maintaining existing electric vehicles in the short term is a more realistic path. The higher the cable current, the larger the cable cross-sectional area required to transmit power at the same voltage level without overheating. This challenge will affect: the high voltage of the charging socket in the car, the cable from the charging socket to the battery pack, the fast charging contactor and the main positive, main and negative contactors, the main fuse, the module terminal block, the internal terminal block of the battery cell, etc. Operating status.

The professional production and R&D team discovered that the important point is the continuous static current from 10 seconds to 20 minutes during R&D. In early production, it was found that because the current fluctuates, although the peak point of the power demand of the entire drive is relatively high, the duration will only last for 10 seconds and then decrease. The total current can be accomplished using the rms design.

In DC fast charging designs, the process of power dissipation is heating of wires, cables and contact resistors, which changes as the temperature increases during operation.

Among them, during certain life cycles, certain high-impedance or heat-restricted areas may become thermal management bottlenecks. If the heat cannot be fully dissipated, the heating process will not be affected by the outside world. According to the existing mainstream designs, current testing mainly focuses on designs below 300A.

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