Structural Design of High Voltage Cables for Electric Vehicles

Standard products and very specific requirements are difficult to define. The purpose of this paper is to address basic design ideas to overcome the challenges described above by applying advanced high voltage cable construction principles.

1. Conductor design The flexibility of high-voltage cables is mostly determined by the design of the conductor. This is why high-voltage cables use special conductors with a large number of monofilaments of very small diameters. A certain number of monofilaments are first stranded and then re-stranded concentrically to form the soft conductor required for high voltage cables. Another advantage of the large number of strands is better resistance to bending. The shorter strand pitch also improves the bending life of high voltage cables. 2. Insulation Materials Insulation materials are selected primarily for their heat resistance requirements and mechanical strength. Compared with standard battery cables, it is reasonable to choose softer materials so that the specially designed stranded conductors remain flexible.3. Cable-forming cables are usually required to strand the cores when multi-core. In order to compensate for the deformation caused by stranding high-voltage cable cores, the so-called de-twisting of the special equipment. In this process, the special stranding machine is equipped with a pay-off disk rotating in the reverse direction relative to the stranding direction. This is necessary to prevent deformation of the cable tension. Depending on the construction of the cable, filling is usually used to ensure a high degree of concentricity of the shielded cable and ultimately to obtain a satisfactory high-voltage cable. The use of wrapping tape in the stranded cable core maintains the flexibility of the cable.4. Shielding Due to EMC (Electro Magnetic Compatibility) requirements, multiple copper wires are used to form a braided shield. Tinned copper wire makes it more resistant to environmental effects such as oxidation. The use of thin copper wires maintains the flexibility of the design The shielding needs to have a coverage of more than 90% to overcome the EMI problems described earlier. The shielding effect varies depending on the need, braided shielding can be combined with a variety of other shielding such as aluminum composite conforming film. A non-woven fabric can be wrapped around the shield to ensure that the sheath can be easily peeled off during assembly. 5. As with the core insulation, the sheath material is selected according to the thermal and mechanical requirements. Environmental properties such as resistance to liquids and abrasion are also particularly important for the sheath due to direct contact. These properties depend mainly on the type of sheath material selected and to some extent on the design of the sheath construction. If special requirements, such as overcoming abrasion from the environment of the vehicle in which it is installed, require increased abrasion resistance, this needs to be taken into account when selecting the material. Test equipment is often used to simulate real-life conditions to verify these properties.

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