EVCOME EV charging stations for better life---Top EV charging stations manufacturers & suppliers in China.
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EVCOME EV charging stations for better life---Top EV charging stations manufacturers & suppliers in China.
The choice of insulating material is mainly to consider heat resistance and mechanical strength. Compared to standard battery cables, the soft material can be rationally selected, maintaining the flexibility of the specially designed stranded conductors. The basic difference from traditional automotive cables is that the structure needs to be designed according to the rated voltage of 600V. If it is used in commercial vehicles and buses, the rated voltage can reach more than 1000V. Cables driven by internal combustion engines are designed for a rated voltage of 60V. Such high voltages have never been a challenge for all insulating materials. This is still a low voltage for industrial and domestic electrical systems. For automotive high voltage cables, the challenge should be hot. Mechanical behavior. High voltage cables need to carry high currents as the cables connect to batteries, inverters and motors. Depending on the power requirements of the system components, the current can reach 250A to 450A. Such high currents are hard to find on conventionally driven vehicles. High current transfer results in high power dissipation and component heating. Therefore, high voltage cables are designed to withstand higher temperatures. At present, the temperature requirement has a tendency to further increase. In contrast, current vehicles typically use cables rated up to 105°C, as long as the cables are not used in the engine compartment or other high-temperature-resistant areas. High-voltage cables for electric vehicles are usually higher than this temperature, such as Class C (125°C) or Class D (150°C). If the routing of electric vehicles is unfavorable, such as near the exhaust pipe, the front of the motor, the back of the battery, etc., the OEM will even put forward higher requirements for high temperature resistance. Such as grade E (175°C) °C. The high heat resistance of the insulating material determines that the cable can withstand a higher rated load flow. The automotive industry usually designs cables at specified temperature classes with a service life of 3000h. In recognized cable standards (such as GB/T25085, GB/T25087, QC/T1037 and ISO19642), it is usually used for long-term aging tests. Customers' special requirements in the field of high-voltage applications may exceed 3000h, and the cumulative running time at the specified temperature may even reach 12000h. The heat resistance of insulating materials is directly proportional to the service life. The more heat-resistant the cable, the longer it will last. In many cases, the challenge with the development of electric vehicles is that the space contains more electrical components. Cables and connectors also need room to route through. It often results in tight bend radii. Due to the inherent design of conventional cables, high bending forces are difficult to overcome. To solve this problem, the high flexibility of the high-voltage cables is crucial. Only with a more flexible design, it can be easily realized by the routing of the vehicle. If the motor is located close to the moving part of the vehicle and then causes continuous vibration of the connected high voltage cables, it needs to be designed for high cyclic bending to ensure good bending resistance. At present, the insulation materials of high-voltage cables are mainly cross-linked polyolefin and silicone rubber. Cross-linked polyolefins have heat resistance up to class D, high mechanical strength and resistance to the chemical influence of liquids. The outer diameter that can be designed is more refined. For grade D cross-linked polyolefin, silicone rubber has excellent heat resistance and flexibility, is environmentally friendly, and is the material of choice for designing higher heat-resistant grade E high-voltage cables. Due to the increased application risk brought by high voltage, high voltage cables must be visually distinguished from ordinary automotive cables, and the specified surface must be bright orange. At the same time, warning content and special signs can also be printed, such as Caution! High voltage 600V. High voltage lightning logo, etc. According to QC/T414, orange is the main color of high voltage wires (cables), specially for rated voltage>AC30V/DC60V. In order to distinguish different circuits of the high-voltage electrical system, it is allowed to use longitudinal color bars as auxiliary colors. See Table 1 for preferred secondary colors. The auxiliary color of the sheathed cable can only be added to the insulation of the cable core and can be used as the main color. The insulation of the cable cores can also be true-coloured (uncoloured) if the single-core sheathed cable has been clearly identified on the sheath. .
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