The Requirements for New Energy Vehicle Wiring Harness Insulation (1)

New energy vehicles refer to the use of unconventional vehicle fuels as the power source (or the use of conventional vehicle fuels, the use of new vehicle power units), the integration of advanced technologies in vehicle power control and driving, and the formation of advanced technical principles. New technology, new structure of the car. There are many new energy vehicle wiring harnesses produced and processed in our factory, including energy storage wire harness, new energy power Wiring Harness, and automotive fan Cable Assembly. The insulation material requirements of automotive wiring harnesses are relatively high, so special care should be taken when selecting materials.

The selection of insulating materials is mainly based on heat resistance requirements and mechanical strength. Compared to standard battery cables, softer materials can be reasonably chosen to keep the specially designed stranded conductors flexible.

The basic difference from conventional automotive cables is that the structure needs to be designed for a rated voltage of 600 V, while if used in commercial vehicles and buses, the rated voltage can be as high as 1000 V or more. The cables currently used in vehicles powered by internal combustion engines are designed for a rated voltage of 60 V.

With all insulating materials, such high voltages are never a challenge. For industrial and domestic electrical systems, this is still low voltage. For automotive high-voltage cables, the challenge should be in thermal and mechanical properties.

High-voltage cables need to carry high currents as cables connect batteries, inverters and motors. Depending on the power requirements of the system components, the current can reach 250A to 450A. Such high currents are hard to find on conventionally driven vehicles. High current transfer results in high power consumption and heating of components. Therefore high voltage cables are designed to withstand higher temperatures. At present, it can be seen that there is a further increase in the temperature requirements.

In contrast, current vehicles typically use cables rated for a temperature of 105°C, as long as the cables are not used in the engine compartment or other areas that are resistant to higher temperatures. Electric vehicle high-voltage cables are usually higher than this temperature, such as Class C (125°C) or Class D (150°C). If the route through the electric vehicle is unfavorable, such as near the exhaust pipe, in front of the motor, behind the battery, etc., the OEM will even put forward higher requirements for high temperature resistance. Such as E grade (175 ℃). The higher heat resistance of the insulating material determines that the cable can carry a higher rated capacity.