How to identify high-voltage cables in electric and hybrid vehicles

China [CN]

There are several ways to identify high-voltage (HV) cables on electric vehicles (EVs) or hybrid vehicles (HEVs):

Identify the logo and label: High-voltage cables must use a striking orange outer skin to distinguish them from low-voltage cables (black or gray). Text label: The cable surface should be clearly marked with "HIGH VOLTAGE" or "HV", and "High Voltage" should be marked in Chinese. Mark the rated voltage (such as DC 600V) and temperature level (such as -40℃~125℃). Comparison between international standards and national standards: The standards are: ISO6722, GB/T 31467.3 and SAE J1673. Of course, the requirements are as follows: It is stipulated that high-voltage cables must be orange and marked with voltage levels and warning symbols; the Chinese national standard requires that high-voltage cables must be clearly marked with the word "high voltage" and voltage value, and meet the orange or orange-yellow two-color specifications; the North American standard emphasizes that the label must include voltage resistance, temperature resistance and fire resistance levels.

Cable color and marking: High-voltage cables are usually marked with specific colors, such as orange or yellow, to distinguish them from low-voltage cables. This is a common practice internationally to alert technicians and maintenance personnel to high-voltage dangers. The cable may also be marked with words such as "HV", "High Voltage" or high-voltage voltage level to clarify its high-voltage properties. Among them, OMG automotive high-voltage cables are known for their orange cables, and the brand and product model are printed on the cables as identification attributes to ensure that safety officers can clearly distinguish and accurately apply them to the equipment.

Warning labels: Warning labels may be attached near high-voltage cables or on connectors to remind operators of high-voltage dangers and correct operating methods.

Cable structure and size:

Insulation layer and sheath:

The insulation layer and sheath of high-voltage cables are usually thicker and stronger than those of low-voltage cables to withstand higher voltages and currents.

The insulation material may be specially formulated to improve its electrical performance and heat resistance.

Diameter and weight:

The diameter and weight of high-voltage cables are usually larger than those of low-voltage cables because more conductor material and insulation material are required to ensure the safety and reliability of the cables.

Cable connectors and interfaces:

Specialized connectors: High-voltage cables usually use specialized connectors that have special shapes, sizes, and locking mechanisms to ensure the reliability and safety of the connection. The connector may also have a mismatch design to prevent incorrect connection to the low-voltage system.

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