The Electric vehicle wiring harness regular, the new energy vehicle marketplace is developing rapidly, but you will see a series of problems. To put it simply, new energy vehicles mainly make reference to technologies that use unconventional vehicle fuel like a power source (or use traditional vehicle fuels, adopt new automobile power units), and integrate sophisticated technologies in vehicle power manage and drive. A car along with advanced principles, new technology as well as new structure. Mainly include real electric vehicles, extended-range electric automobiles, hybrid vehicles, fuel cell electric vehicles, hydrogen engine vehicles, along with other new energy vehicles.
But whatever the form of new energy automobiles, their common feature is using voltage platforms up to 300V ~ 600V or more, involving wiring, and they all possess the same basic requirements, that is actually, under the electromagnetic interference safety system. Safely transmit high currents as well as voltages. The high-voltage cable can be used to connect high-voltage batteries, inverters, air-conditioning compressors, three-phase generators and electric motors to understand the transmission of power as well as power. However, it should be noted how the high-voltage harness of an electric vehicle isn't equivalent to the high-voltage power transmission cable within our daily life but is relatively in accordance with the low-voltage system of a regular automobile.
Electric vehicle wiring harness standard: requirements with regard to high-voltage wiring harness for electrical vehicles
The basic difference from traditional automotive cables is that the structure must be designed for a rated voltage associated with 600 V, and if utilized on commercial vehicles and buses, the rated voltage is often as high as 1000 V. In contrast, it is even higher. Cables currently used in cars driven by internal combustion engines are made to have a rated voltage associated with 60 V.
In the case in which the generated power (P = Ough × I) is constant, the high voltage can slow up the power loss in the tranny system (PLOSS = I2 × R) because of the use of a lower present.
Since the cable television connects the battery, the inverter and also the motor, the high voltage cable must transmit a high current. The current can reach 250A to 450A with respect to the power requirements of the program components. Such high currents are difficult to acquire on conventionally driven vehicles.
The result of high current transmission leads to high power consumption and heating from the components. High voltage cables are therefore made to withstand higher temperatures. It is visible that there is a inclination for further increase in heat requirements.
In contrast, current vehicles typically make use of a cable rated at 105 ° D, as long as the cable isn't used in the engine compartment or the areas that are resistant to greater temperatures. Electric vehicle high voltage cables are often higher than this temperature, for example 125 ° C or a hundred and fifty ° C.
If the route passed with the motorized car is unfavorable, the OEM may even propose higher temperature resistance needs. Such as near the wear out pipe, the front of the actual motor, the back of the actual battery, etc.
4. Working existence
The automotive industry typically includes a designed service life of 3000 h in a specified temperature grade. In acknowledged cable standards (eg ISO 6722, ISO 14572), this value is usually used for long-term aging assessments. The special requirements of clients in high-voltage applications may surpass 3000 h, and the cumulative operating time at specified temperatures might even reach 12, 000 h.
5. Protecting effect
The high voltage cable itself doesn't need to be shielded because it doesn't transmit data like a coaxial cable television, but it is necessary to avoid or reduce the high frequency radiation generated through the switching power supply in the machine from being induced to the peripheral components with the cable.
Unlike fuel-driven vehicles, three-phase alternating electric current that controls the electric motor's motors becomes essential. The sinusoidal voltage carrying energy is the same as a square wave pulse transmission of different frequencies. Since the high frequency pulse includes a steep edge, it generates an extremely strong harmonic emission to the encompassing area.
The EMI problem could be completely solved by using a suitable shielding method. In some instances, a combination of different shielding types is needed to meet the different requirements from the shielding effect.
The challenge in the development of hybrid vehicles oftentimes is that the existing number of platforms originally only designed the area for loading the gasoline engine and it is components into more electrical elements. Even if wiring is not really considered, space limitations can be anticipated. In addition, cables and fittings also require space for redirecting. The usual consequence is the bending radius leading to tension.
Due to the actual inherent design of conventional wires, high bending forces are hard to overcome. To solve this issue, the high flexibility of high voltage cables is crucial. Only a more flexible design could be easily implemented by routing the automobile.
7. Resistance to bending
If the motor is located near to the moving part of the vehicle after which causes the connected high-voltage cable television to continuously vibrate, it is needed to be designed to withstand high cyclic bending to make sure good bending endurance.
Because of the increased application risk because of high voltages, various standards define that high-voltage cables should be visually distinguished from ordinary auto cables, and the designated surface should be bright orange.
At the exact same time, warning content and special marks could be printed, such as "Caution! Higher voltage 600V", high voltage super logo.
Electric Vehicle Harness Regular: Standardization Status of Electric Automobile Cable
In response to the above mentioned challenges and requirements for higher voltage cables for electric automobile applications, it is necessary to determine new cable standards to satisfy the needs of suppliers, wire funnel plants and OEMs.
This work has been carried out by the Automotive Cable Division from the Electrical and Electronic Subcommittee from the International Organization for Standardization Street Vehicle Technical Committee (ISO/TC 22/SC 3/WG4).
Because seen on ISO 6722, it's been revised based on the typical 600 V cable standard to satisfy the requirements of 600V cable television. Because most of its requirements continue to be very versatile, the special design necessary for high voltage cables is frequently not considered. A similar revision was designed to ISO 14572.
The standardization of high voltage cables with voltages greater than 600V is currently a topic for every working group. The standard quantity is ISO 17195.
SAE will adjust the present high voltage (600 V rating) standards SAE J1654 for high voltage wires and cover voltage ratings through 600 to 1000 V. The newly created standard SAE J2840 is going to be defined as a shield kind cable.
LV is the typical procurement standard of Germany's 5 major auto companies, and currently introduces the conventional LV 216 for high-voltage cables for electric vehicles having a rated voltage of 600 Sixth is v. It covers single-core and multi-core protected cables. China's national automotive industry requirements for high-voltage shielded cables are now being developed, and their rated voltage may reach 1000 V.