Design and development of high voltage cables for electric vehicles

- Oct 02, 2019-

Electric vehicles mainly include three types, namely pure electric vehicles, hybrid vehicles and fuel cell vehicles.

The rising international crude oil price, the whole society's concern about the global warming of environmental degradation, coupled with the tilt of government taxation and policy support, have led to a growing market share of alternative energy sources, especially electric vehicles, worldwide.


Electric vehicles mainly include three types, namely pure electric vehicles, hybrid vehicles and fuel cell vehicles. Pure electric vehicles and fuel cell vehicles are driven entirely by an electric motor, which is combined with an internal combustion engine and an electric motor, and is supported by an electric motor when the efficiency of the internal combustion engine is not high under acceleration and low speed conditions. Their common feature is the use of drive voltages of up to 600V or higher, involving wiring, they all have the same basic requirements, both safely transmitting high currents and voltages under EMI (electromagnetic interference) protection systems. As a high-voltage cable, it is used to connect high-voltage batteries, inverters, air-conditioning compressors, three-phase generators and electric motors to realize the transmission of power and power.


The basic principle of electric vehicles seems to be simple. But in-depth analysis, system manufacturers are facing a series of challenges that need to be overcome. For electric vehicle high-voltage cables, new requirements for flexibility, shielding, safety, and size have been proposed because they affect the wiring of high-current and high-voltage components. In the face of the different technical points of each possible power system, different special requirements are also imposed on the required components.


It should be noted that the high voltage system of the electric vehicle is not a typical high voltage system, and related terms such as "high voltage" and "high current" must be limited only in the automotive field, as opposed to the low voltage system of a conventional automobile. Reference systems in other fields use completely different standards, such as the high voltage definition in the power sector, which starts at several thousand volts.

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