Design and development of high voltage cables for electric vehicles

With the continuous rise in international crude oil prices, the growing concern of the whole society about environmental deterioration and global warming, and the tax incentives and policy support from various governments, the market share of new energy, especially electric vehicles, continues to expand and develop globally.
There are mainly three categories of electric vehicles: pure electric vehicles, hybrid vehicles, and fuel cell vehicles. Pure electric vehicles and fuel cell vehicles are driven only by electric motors, while hybrid vehicles combine an internal combustion engine with an electric motor, and the electric motor provides support during acceleration and low speeds when the internal combustion engine is inefficient. The common feature is that they can use driving voltages up to 600V and above. In terms of wiring, they have the same basic requirement of safely transmitting high currents and voltages under EMI (electromagnetic interference) protection systems. As a high-voltage cable, it connects high-voltage batteries, inverters, air conditioning compressors, three-phase generators, motors, etc., to realize the transmission of power or electrical energy. The basic
principle of electric vehicles seems simple. However, digging deeper, system manufacturers are faced with a series of challenges that need to be overcome. High-voltage cables for electric vehicles affect the wiring of high-current and high-voltage components, so new technical requirements are laid down for flexibility, shielding, safety, size, etc. Faced with the different technical aspects of each possible power system, various special requirements are also put forward for the necessary components. It should be noted
that the high-voltage system of an electric vehicle is not a typical high-voltage system. Related terms such as "high voltage" and "high current" must be limited to the automotive sector, as opposed to the low-voltage systems of conventional vehicles. In other sectors, completely different standards are used for the reference systems. For example, the definition of high voltage in the power sector starts from several thousand volts.