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 new energy vehicle system is very different from the traditional fuel vehicle architecture. For example, the new energy vehicle high-voltage cable system has various technical requirements for connecting high-voltage batteries, inverters, motors and other components. This article focuses on the requirements of new energy vehicles for high-voltage cables. 1. Voltage At present, the rated voltage of cables used in traditional vehicles driven by internal combustion engines is designed to be 60V. The basic difference from traditional fuel vehicle cables is that they need to be designed according to the structure with a rated voltage of 600V. If used in commercial vehicles and buses, the rated voltage can reach 1000V. 2. Current Because the internal cables of new energy vehicles are connected to components such as batteries, inverters, and motors, high-voltage cables need to transmit higher currents. Depending on the power requirements of the system components, the current can reach 250A to 450A, or even higher. 3. Temperature The result of high current transmission results in high power consumption and component heating, so high voltage cables must be designed to withstand higher temperature ranges. In contrast, conventional fuel-powered vehicles typically use cables rated to a temperature limit of 105°C unless the cable is used in the engine compartment or other high-temperature-resistant areas. The high-voltage cables of new energy vehicles are usually higher than the limit temperature of general-purpose fuel vehicles, reaching 125°C or 150°C. If there are other influencing factors in the loop through which new energy vehicles pass, original equipment manufacturers will even put forward higher requirements for high temperature resistance. Such as the vicinity of the exhaust pipe, the front of the motor, the back of the battery, etc. 4. Working life. The automotive industry is typically at specified temperature levels and cables are designed for a life of 3000 hours. In recognized cable standards such as ISO672.ISO14572, this setting is usually used for long-term aging tests. In the field of high-voltage applications, due to the special requirements of customers, the service life of the cable design may exceed 3,000 hours, and the cumulative operating time at the specified temperature may even reach 12,000 hours. The heat resistance of the insulation material is directly proportional to the service life, the longer the service life of the cable. 5. Shielding effect. New energy vehicle high-voltage cables themselves do not need shielding, because data transmission is not like coaxial cables, but it is necessary to prevent or reduce the high-frequency radiation generated by switching power supplies in the system from being transmitted to surrounding key equipment components through cables. Unlike fuel-driven vehicles, the motors that control new energy vehicles mainly use three-phase alternating current, and the voltage that carries energy is composed of signals of different frequencies. Due to the steep edge of the high-frequency pulse, strong energy harmonics are emitted to the surrounding area. EMI problems can be completely resolved by using proper shielding methods. In some cases, different types of shielding combinations are required to meet different requirements for shielding effects. 6. Flexibility In many cases, the challenge faced by the development of new energy vehicles is that the existing series platforms are only designed to load the gasoline engine and its components, and more electrical components are incorporated into it. Even if wiring is not a consideration, space constraints must also be considered. At the same time, cables and connectors also need space for routing. The usual consequence is a tight bend radius. Due to the inherent design of conventional cables, high bending forces are difficult to overcome. To solve this problem, the high flexibility of high voltage cables is very important. Flexible design is only possible with ease through the tight paths inside electric vehicles. 7. Bending resistance If the internal motor of a new energy vehicle is located close to the moving part of the vehicle, it will cause continuous vibration of the connected high-voltage cable, which needs to be designed for high-cycle bending to ensure good bending resistance. 8. Marking Due to the increased application risk brought by high voltage, various standards define that high voltage cables must be visually distinguished from cables for general fuel vehicles, and the specified surface must be bright orange. At the same time, it is also possible to print warning content and special signs, such as Caution! High voltage 600V. High voltage lightning logo, etc. According to QC/T414, orange is specially used for rated voltage>The main color of AC30V/DC60V high-voltage wires (cables). In order to distinguish the different circuits of the high-voltage electrical system, vertical color bars are allowed as secondary colors. .
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