Design Requirements for High Voltage Wire Harnesses for Electric Vehicles

I. Requirements for high-voltage wiring harnesses for electric vehicles 1. The basic difference between voltage and conventional automotive cables is that the structure needs to be designed for a rated voltage of 600 V, whereas if used in commercial vehicles and buses, the rated voltage can be as high as 1,000 V. By comparison, it is even higher. The cables currently used in vehicles driven by internal combustion engines are designed for a rated voltage of 60 V. The system produces a constant power (P = U x I), and the high voltage reduces the power loss in the transmission system (PLOSS = I2 x R) due to the use of lower currents.2. CURRENT CURRENT Since the cables connect the batteries, inverters, and electric motors, the high-voltage cables are required to transmit high currents. Depending on the power requirements of the system components, currents can reach 250 A to 450 A. Such high currents are difficult to find in conventionally driven vehicles.3. TemperatureThe result of high current transmission leads to high power consumption and heating of the components. Therefore high voltage cables are designed to withstand high temperatures. A trend towards a further increase in temperature requirements can currently be observed. In contrast, current vehicles usually use cables rated up to 105°C as long as the cables are not used in engine compartments or other areas that are resistant to higher temperatures. High-voltage cables for electric vehicles are usually rated above this temperature, such as 125°C or 150°C. OEMs may even demand higher temperature resistance if the routing through the electrified vehicle is unfavorable. For example, near the exhaust pipe, in front of the motor, at the back of the battery, etc. 4. Operating life The automotive industry usually designs cables for a service life of 3000 h at specified temperature levels. In recognized cable standards (e.g. ISO 6722, ISO 14572) this value is usually used for long-term aging tests. Customer-specific requirements in high-voltage applications may exceed 3000 h, and the cumulative operating time at the specified temperature may even reach up to 12000 h. 5. Shielding Effectiveness High-voltage cables do not need to be shielded per se, since they do not transmit data as coaxial cables do, but it is necessary to prevent or minimize the high-frequency radiation generated by switching power supplies in the system from being induced through the cables and into the peripheral components. Unlike fuel-driven vehicles, three-phase AC power to control the motor of an electric vehicle becomes necessary. The sinusoidal voltage carrying the energy corresponds to square wave pulse signals of different frequencies. Since high frequency pulses have steep edges, very energetic harmonics are emitted into the surrounding area. EMI problems can be completely solved by using appropriate shielding methods. In some cases a combination of different shielding types is required to meet the different requirements for shielding effectiveness.6. Flexible Hybrid Vehicle Development The challenge in many cases is that the existing family of platforms originally designed to carry only the gasoline engine and it's components has space to incorporate more electrical components. Space constraints can be expected even without considering wiring. In addition, cables and connectors routed through also require space. The usual consequence is that this leads to tight bending radii. Due to the inherent design of conventional cables, high bending forces are difficult to overcome. To solve this problem, high flexibility of high voltage cables is essential. Only with a more flexible design can routing through the vehicle be easily achieved.7. Bending resistanceIf the motor is located close to a moving part of the vehicle, which then causes continuous vibration of the connected HV cable, it is required to be designed to withstand high cyclic bending to ensure good bending resistance.8. MarkingBecause of the increased risk of applications due to high voltages, various standards define that HV cables have to be visually distinguishable from regular automotive cables, specifying that the surface must be bright orange. It is also possible to print warnings and special markings such as "Caution! High Voltage 600V", a lightning bolt for high voltage, etc.-2、About Evergrande Electronic Products Network platform related to the introduction and sales of products briefly: Evergrande Electronic Products Network - a professional agent / production / sales of a variety of {connectors | wiring harness | wire and cable products}; if you have a related [connectors | wiring harness | wire and cable products] purchasing / sourcing needs or would like to buy / to understand what connectors | harness | wire and cable products we can provide solutions, please contact the following Division I business personnel; If you have related [connector | wire harness | wire and cable production] sales / resources and promotion needs, please click on the ¡¡ Business Cooperation ← ¡" to discuss with a person!