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Design and development of high voltage cables for electric vehicles

Design and development of high voltage cables for electric vehicles

The continuous rise of international crude oil prices, the whole society's more concern about environmental degradation and global warming, coupled with the tax incentives and policy support of governments, have promoted the continued growth of the market share of new energy, especially electric vehicles. Develop globally. Electric vehicles mainly include three categories, namely pure electric vehicles, hybrid vehicles and fuel cell vehicles. Pure electric vehicles and fuel cell vehicles are powered entirely by electric motors, while hybrid vehicles combine an internal combustion engine and an electric motor, supported by the electric motor during acceleration and low speed situations when the internal combustion engine is not efficient. What they all have in common is the use of drive voltages up to 600V or higher. In terms of wiring, they all have the same basic requirement, which is to safely transmit large currents and voltages under an EMI (electromagnetic interference) protection system. As a high-voltage cable, it is used to connect high-voltage batteries, inverters, air-conditioning compressors, three-phase generators and motors to realize the transmission of power and electric energy. The fundamentals of electric vehicles seem simple. But digging deeper, system manufacturers are facing a series of challenges to overcome. For electric vehicle high-voltage cables, new technical requirements are put forward for items such as flexibility, shielding, safety, and size, because these will affect the wiring of high-current and high-voltage components. Facing the different technical points of each possible power system, different special requirements are also put forward for the required components. It should be noted that the high-voltage system of electric vehicles is not a typical high-voltage system, and related terms such as "high voltage" and "high current" must be limited to the scope of the automotive field, as opposed to the low-voltage system used in traditional vehicles. In other fields, reference systems use entirely different standards. For example, the definition of high voltage in the electric power field starts from several thousand volts.

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Take you to understand the high-voltage electrical system of pure electric vehicles

Take you to understand the high-voltage electrical system of pure electric vehicles

Pure electric vehicles use power batteries as energy sources, and their electrical systems include high-voltage electrical systems, low-voltage electrical systems and CAN communication information network systems. This article briefly introduces the composition and development trend of high voltage electrical system. >>>> Composition of high voltage electrical system In pure electric vehicles, the high-voltage electrical system mainly undertakes functions such as starting, driving, charging and discharging, and air-conditioning power. It mainly includes battery system, powertrain, high-voltage electronic control system, charging system, high-voltage equipment and its wiring harness system. Pure electric vehicle high voltage electrical system battery system Power battery PACK assembly: the "heart" of electric vehicles, which provides energy for various systems of the vehicle. When the power is exhausted, it also needs to be charged. The power battery is a high-voltage DC, its working voltage is generally 100~400V, and its output current can reach 300A. Ternary lithium battery is the current mainstream. Generally speaking, the electric vehicle power battery PACK consists of the following parts: power battery module, structural system, electrical system, thermal management system, and battery management system (BMS).

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2023

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The difference between national standard, American standard and European standard cable temperature resistance grade

The difference between national standard, American standard and European standard cable temperature resistance grade

1. UL standard In UL standards, the common temperature resistance grades are 60°C, 70°C, 80°C, 90°C, 105°C, 125°C and 150°C. In fact, these so-called temperature ratings are called rating temperatures in UL standards. It is not the long-term operating temperature of the conductor.

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