Stranding Mode of Core of High Voltage Conductor

The core is the main part of high-voltage conductor, which bears the important responsibility of high-voltage current and voltage transmission. From the point of view of high-voltage conductor core, there are two things that need special attention, namely, the twist mode of core and the material of core.

For high-voltage conductors, the selection of wire harness diameter and the requirements of wiring harness color should be paid more attention to.

The diameter of high-voltage conductor is often several times that of low-voltage conductor. In order to increase the flexibility and flexibility of high-voltage conductor, the conductor core with larger interface is made up of several single wires with smaller diameters. The Cable Harness core twisted by a plurality of single wires has good flexibility. When the wire core is bent, the inner and outer parts of the center line of the wire core can move and compensate each other, and the plastic deformation of the conductor will not be caused when the wire core is bent, so the flexibility and stability of the wire core are greatly improved. Therefore, the vehicle Wiring Harness produced by our company, Kable-X, especially the high-voltage wire, uses multi-strand stranded wire.

The twist forms of the core can be divided into two types: regular twist and irregular twist.

(1) Regular Twisting

Regular, concentric and successive layers of wires are twisted in different directions to form regular twists.

Furthermore, it can be divided into normal regular twisting and abnormal regular twisting. The latter refers to the regular twisting of wires with different diameters between layers, while the former refers to the same diameter of wires.

Regular stranding can also be subdivided into simple regular stranding and compound regular stranding. The latter means that the wires that make up regular stranding are not single, but thinner wires that are twisted into strands according to rules and then twisted into cores. This kind of stranding is mostly used to move the cores of rubber insulated cables to improve their flexibility.

(2) Irregular Twisting

It means that all the constituent wires are twisted in the same direction.

The twist of the core is also designed to other related process parameters, including twist pitch, twist coefficient, twist direction, twist rule, etc.

Considering the production process and process requirements, the high-voltage wires of electric vehicles are usually twisted in a normal and regular way, which is conducive to mechanized and automated production.

As a conductive material, metals need to have the innate advantages of excellent conductivity, sufficient mechanical strength, resistance to oxidation, corrosion, easy processing, easy welding and abundant resources. As far as single conductor performance is concerned, silver is the best, followed by copper and aluminum.

The core wire of high-voltage conductor generally adopts single metal. According to the material classification, it can be divided into copper wire (including tinned copper wire, annealed soft copper wire and hard copper wire) and aluminum wire.

(1) Properties and Main Characteristics of Metallic Copper

And has good electrical and thermal conductivity. The conductivity of copper is second only to silver, and the thermal conductivity of copper is second only to gold.

(2) Classification of Copper Wires

Hard copper wire: it is cold-worked by wire extension, and has high tensile strength. It is suitable for conductors of overhead transmission lines, distribution lines and construction lines.

Soft copper wire: hard copper wire is heated to remove the residual stress caused by cold working, which is rich in softness and flexibility, and has high conductivity. It is used to manufacture conductors of communication and power cables, electrical machinery and wires of various household appliances.

Tinned copper wire: the surface of copper wire is tinned to increase weldability, protect copper conductor from corrosion when PVC or rubber insulation is extruded, and prevent aging of rubber insulation. Generally, tinned copper wire is used for high-voltage cables with temperature resistance of 150℃ or above.

(3) Properties and Main Characteristics of Metallic Aluminum

· The conductivity of aluminum is second only to that of gold, silver and copper, which is 62% of that of copper.

· Good thermal conductivity.

· Good corrosion resistance, easy to form oxide film and prevent aluminum oxidation.

· The mechanical strength of pure aluminum is average.

· Metal has good aluminum-plastic properties, and can be made into various products by pressure processing.

· Aluminum has low density, low price and reliable source.

· As a conductive material, aluminum has low tensile strength and poor weldability.

(4) Comparison of electrical properties between metallic copper and metallic aluminum.

Due to the low tensile strength, low density, light weight and low cost of metal aluminum conductor, many large square high-voltage conductors in the market have chosen to use aluminum conductor instead of copper conductor, which can indirectly contribute to the lightweight of the whole vehicle and achieve the purpose of reducing the cost of the whole vehicle.