Special process design in automotive high voltage cables

Automotive high-voltage cables are standard for pure copper cores, which can be composed of multiple thin copper cores. The electrical conductivity increases. When there is an alternating current or an alternating magnetic field in the conductor, a "skin effect" will occur, and the current will be concentrated in the "skin part" of the wire, and the current density on the conductor surface is greater than the current density in the center. Roughly speaking, it can be understood that the primary conductor conducts electricity through a surface.

Of course, the higher the frequency of alternating current, the more obvious the "skin effect". The high voltage platform of new energy vehicles is 300-400V, and the frequency can reach the kHz level, which is dozens of times higher than household appliances, so the high voltage wiring harness must reduce the "core" area. To take an extreme example, assuming that the wire is infinitely thin, it can be seen that the entire wire conducts electricity, and the conductivity of a high-voltage wire harness consisting of an infinite number of thin wires can be significantly enhanced. There are other benefits, too. The main high-voltage harness has a cross-sectional area of 50mm², which is 5-10 times thicker than household electricity. It's harder and harder to bend. Not only is it difficult to lay out in a car, but it can also puncture the cockpit after a crash, increasing safety risks. Considering strength and toughness, as well as safety, multi-core wire is also a better choice.

The vehicle's high-voltage harness has shielding: Maxwell the Great said that electricity produces magnetism. When an electric current passes through the wire, a magnetic field is generated around the wire. The shielding layer can shield electromagnetic fields in the harness without affecting other components, while reducing electromagnetic radiation. It can also shield from external influences and prevent interference from external magnetic fields.

Finally, to sum up, the basic principle of home wiring harness and car wiring harness is the same, are based on the requirements of current and voltage to choose the right harness, not necessarily the thicker the better. In addition, due to more demanding conditions of use, automotive high-voltage wiring harnesses require higher standards and are designed with more details in mind, making them safer and more durable.

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