EV Cable Structure Characteristics

In recent years, the new energy industry has developed rapidly, especially the new energy vehicle industry. As an important part of new energy vehicles--EV cable, what are its main characteristics?

Characteristics of EV cable conductor material

The thickness of the conductor plays a decisive role in the flexibility of electric cables. Generally speaking, a special conductor structure is formed when a single ultra-fine copper wire is wound together. In addition to good elasticity, this conductor structure also has strong bending resistance and long service life.

Characteristics of EV cable insulation materials

Thermal resistance and mechanical strength are mainly considered in the selection of insulating materials. According to the use requirements of the product, soft materials can be reasonably selected to keep the specially designed stranded conductor flexible.

EV cable structure characteristics

When the cable is multi-core, the core wire usually needs to be twisted. To compensate for the deformation caused by twisted high-voltage cable cores, a special device called untwisting is required. In this process, the pay-off reel equipped with a special stranding machine rotates reversely relative to the stranding direction. This is necessary to prevent cable deformation and tension. According to the cable structure, fillers are usually used to ensure the high concentricity of shielded cables and obtain satisfactory high-voltage cables. The use of wrapping tape in the twisted cable core can maintain the flexibility of the cable.

Jacket material characteristics

The standard color of the outer sheath is orange as the warning color. The material needs to be selected according to its thermal and mechanical properties. As the sheath is in direct contact with the outside, there are certain requirements for wear resistance.

As the main carrier of electric vehicle power output, high-temperature and high-pressure resistant EV cables are one the key components that determine the performance and safety of the vehicle. The research, development, and design of EV cable should be considered not only from the perspective of the whole vehicle but also from the aspects of raw materials, connectors, parts suppliers, etc. To jointly formulate unified standards that meet the requirements of the current actual use environment and are forward-looking in the industry. Further, improve the safety of electric vehicles, reduce the design and manufacturing costs of new energy harnesses, and make due contributions to the development of the new energy vehicle industry.