A Complete Explanation of the Design and Development of High-voltage Cables for Electric Vehicles

Electric vehicles are developing rapidly, and high-voltage wiring harnesses have attracted much attention as key components. Its design and development are related to vehicle safety and performance. From meeting the needs of high-voltage transmission to coping with complex working conditions, it is full of challenges. How to balance lightweight and cost control while ensuring insulation and shielding performance? This is what this article will discuss.

Shielding effect High-voltage cables themselves do not need to be shielded because they do not transmit data like coaxial cables, but it is necessary to prevent or reduce the high-frequency radiation generated by the switching power supply in the system from being induced to surrounding components through the cable. Unlike fuel-driven vehicles, three-phase alternating current to control the motor of electric vehicles is a must. The energy-carrying sinusoidal voltage is equivalent to a square wave pulse signal of different frequencies. Since high-frequency pulses have steep edges, they will generate very strong harmonics that are emitted to the surrounding area. EMIproblems can be completely solved by using appropriate shielding methods. In some cases, a combination of different shielding types is required to meet different requirements for shielding effects.

The standardization of high-voltage cables with voltages above 600V is a topic of the automotive wire working group. The standard number is ISO 17195. Later it was merged into the new standard project ISO19642 as several parts of the ISO19642-X series of standards. SAE adjusts the current high voltage (rated 600V) specification SAEJ1654 for high voltage cables and covers rated voltages from 600 to 1000 V. The newly created standard SAE J2840 defines shielded type cables. LV is the common procurement specification of the five major automobile companies in Germany. Currently, the electric vehicle high voltage cable standard LV 216 with a rated voltage of 600 V has been launched. It covers single-core and multi-core shielded cables. my country's national automotive industry standard for high-voltage shielded cables has been issued and implemented, and its rated voltage will reach DC1500V/AC1000 V. The standard number is QC/T1037-2016.

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