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April 21, 2022

The Requirements for New Energy Vehicle Wiring Harness Insulation (2)

With the advancement of technology and the growth of the company, our products cover a wider range of fields. The field of new energy has always attracted much attention, especially now that energy is becoming more and more precious, we have to develop and utilize both energy storage and new energy. Our products mainly include medical Wire Harness and Industrial Wire Harness, similar to CT Wire Harness and health equipment Cable Assembly are familiar to people. We also have customized wiring harnesses in the energy storage industry, and we have some understanding of the energy storage industry. Different energy storage technologies have different advantages and disadvantages in terms of life, cost, efficiency, scale, and safety. At the same time, due to different specific conditions, the purpose of energy storage is different, and the choice of energy storage method also depends on the requirements of power generation installed capacity, energy storage duration, charging frequency, floor space, and environmental impact. The representative energy storage wiring harnesses of Kable-X include BMS Wiring Harness, acquisition wiring harness and battery pack wiring harness. Moreover, the three fields of energy storage, new energy and automobile are closely related.

The automotive industry typically has a cable design life of 3000 h at the specified temperature class. In recognized cable standards (such as GB/T 25085, GB/T 25087, QC/T 1037 and ISO 19642), this value is usually used for long-term aging tests. The special requirements of customers in high-pressure applications may exceed 3000 h, and the cumulative operating time at the specified temperature may even reach 12000 h. The heat resistance of the insulating material is proportional to the service life, and the more heat resistant the cable can carry the longer service life.

The challenge in the development of electric vehicles in many cases is the space to incorporate more electrical components. Cables and connectors also need space to route through. Usually results in tight bend radii. High bending forces are difficult to overcome due to the inherent design of conventional cables. To solve this problem, high flexibility of high-voltage cables is crucial. Only a more flexible design, routing through the vehicle can be easily achieved. If the electric motor is located close to a moving part of the vehicle and then causes the connected high voltage cable to vibrate continuously, it needs to be designed to withstand high cyclic bending to ensure good bending endurance.
At present, the insulation materials of high-voltage cables are mainly cross-linked polyolefin and silicone rubber. Cross-linked polyolefins are thermally resistant up to class D and have high mechanical strength and resistance to the influence of liquid chemicals. The outer diameter that can be designed is more refined. For D-class cross-linked polyolefin, it is usually not possible to be halogen-free, while silicone rubber has excellent heat resistance and flexibility, and is environmentally friendly and halogen-free. It is the first choice for designing higher heat-resistant E-class high-voltage cables.
Because high voltage brings increased application risk, according to the standard requirements, high-voltage cables must be visually distinguished from ordinary automotive cables, and the designated surface must be bright orange.

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