Shanghai Richeng Electronics Co. Ltd - ISO9001/IATF16949/ISO/TS22163
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Matching Design of High-voltage Harness Cables for Electric Vehicles

The optional content of the cable is mainly to determine the conductor cut-out and insulation material. At present, high-voltage cables have a mature standard system, and are divided into single-core and multi-core cables, and the main conductors are made of soft copper strands to meet the requirements of internal resistance and soft bending of the wires. The insulation layer requires temperature and flame resistance. Mostly composite structure, common cross-linked polyolefins and PVC material; for electromagnetic radiation protection function, mainly through the bare copper mesh within the insulation layer or the tinned copper mesh outside the cable to achieve shielding, the preparation density of ≥ 90%; According to safety standards, the color of the power cable is orange or an orange jacket.

The main parameters of cable selection are: current carrying capacity, conductor resistance, thermal resistance, temperature resistance, etc. It can be designed and matched according to the cable temperature rise and current carrying capacity curve in the manufacturer's data, or according to empirical parameters.

The motor load operation will appear short-term overload phenomenon, so cable should be considered when the load-carrying capacity to meet the long-term operating conditions of the vehicle, the cable over-current duration is relatively short, the heat is less outward diffusion, so you can not consider the heat dissipation process, Approximate heat generation for conductor temperature rise

Still taking the motor drive cable as an example, if a cable with a temperature resistance of 125°C and a product size of 35 mm2 is used, the continuous operating current is 158 A, and the cable's sustainable running time at the peak current is 150 s. . Use the same method to find the recommended wire diameter for each cable.

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