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Main characteristics of high-voltage conductors for hybrid and electric vehicles include:
1 Rated voltage
The rated voltage of the conductor is the AC/DC limited voltage value that the conductor can sustain continuously without degrading the basic characteristics of the conductor.
In the loop of the battery system, the maximum rated voltage can reach 600V DC, so it is necessary to pay special attention to the manufacturer's regulations on the working voltage of the wire harness when selecting the wire. The rated voltage of the conductor should be greater than the maximum voltage of the loop.
2 Amp Capacity
Ampere capacity of conductor is the result of many factors. Such as wire size, wire material and wire length.
The ampere capacity and allowable temperature rise of the conductor are closely related to the cross-sectional area of the conductor specification. It can be preliminarily selected according to the smoke curve of a wire with a specific specification.
3 Working Temperature
The working temperature of conductor can be divided into continuous working temperature and maximum overload temperature. These temperatures can be measured by measuring the insulation surface of the wiring harness.
The continuous temperature is the temperature at which the insulation layer of the wire bears for 3000 hours (quoted from ISO standard) and there is no abnormality. This temperature is obtained by measuring the surface of the insulation layer of the wiring loom. The total temperature of the conductor caused by the allowable steady-state (continuous) current is less than the continuous working temperature. For the continuous working state, the definition of steady-state ampere capacity of a conductor at a given ambient temperature refers to a specific current, which the conductor can sustain for 3000 hours and will not exceed the continuous working temperature of the insulation layer.
4 Maximum Overload Temperature
The maximum overload temperature refers to 60℃ on the basis of continuous working temperature of conductor insulation layer. The wire can withstand this temperature for one hour. The allowable overload current will cause the total conductor temperature to be less than the overload working temperature. Overload may shorten the overall life of the conductor, but it will not cause damage to the conductor.
5 Thermal Effect of Short-Circuit Current -I²t
When a short circuit occurs, a lot of heat energy will be generated. The heat resistance of I²t for measuring short-circuit current is an important performance parameter of high-voltage conductors. I stands for short-circuit current (RMS), and T stands for short-circuit time (unit second).
6 Conductor Smoke Curve
This curve shows the phenomenon that occurs when the current exceeds a specific level at a specific time and the wire smokes.
The Steps of Preliminary Wire Selection Are as Follows:
Firstly, according to the customer's information of applied electrical equipment, current, voltage and temperature requirements, combined with M-Spec specification, the potential feasible harness specifications, such as M6040 specification series, are screened from BOD documents.
Obtain the required wire smoke curve from the supplier, like Kable-X, and preliminarily select the feasible wire diameter specification, such as cross-sectional area of 35mm² or 50mm², through the current and core temperature curve.
For example, the ambient temperature of the client device is 85℃, and the working current is required to be 200A, while we determine the wire diameter by the smoke curve of M6040.
Input the selected wire diameter specification information into "CableSimulationTool" according to the following input information list, and obtain the corresponding "gauge-current-temperature rise". Through the obtained temperature rise curve, we can further verify the temperature rise of the selected wire under the customer's specified working current and temperature environment requirements, and confirm whether it exceeds the limit working temperature of the selected wire itself.
Fuse, wire matching simulation and Wire Harness selection and upgrading. The "gauge-current-temperature measurement security" calculated by the "CableSimulationTool" is input into the "fuse/wire selection and matching tool", and the system will automatically calculate and simulate the wire diameter specification matching the corresponding fuse through a series of formulas.
When the system simulates the wire performance and fuse matching, when the calculation fails, it will automatically upgrade and recalculate the initial wire diameter specification until all calculation conditions are met, and output the final wire diameter specification to complete the wire selection.
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Privacy statement: Your privacy is very important to Us. Our company promises not to disclose your personal information to any external company with out your explicit permission.