High-voltage electrical system is one of the core components of electric vehicles. As a key component of the high-voltage electrical system, the high-voltage wiring harness provides a guarantee for the safety of electric vehicle operation.
The innovative electric vehicle design presents new challenges to the high-voltage cables and system components. New technical requirements are imposed on the electric vehicle high-voltage cables, their flexibility, shielding, safety, dimensions and other items, as these affect the wiring of high-current and high-voltage components.

The specific requirements are analyzed as follows.
1. voltage
The basic difference with 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 up to 1000 V. In comparison, it is even higher. The cables currently used in cars driven by internal combustion engines are designed for a rated voltage of 60 V.
2. Current
Since the cable connects the battery, inverter and motor, the high-voltage cable needs to carry high currents. Depending on the power requirements of the system components, currents can reach 250 A to 450 A. Such high currents are difficult to find in conventionally driven vehicles.

3. Operating life
The automotive industry typically designs cables for a service life of 3000 h at specified temperature levels. in recognized cable standards (e.g. ISO 6722, ISO 14572), this value is usually used for long-term aging tests. Customer-specific requirements in high-voltage applications may exceed 3000 h and even reach up to 12000 h cumulative operating time at the specified temperature.

4. Shielding effect
High-voltage cables do not require shielding per se, since they do not transmit data like coaxial cables, but they need to prevent or reduce the high-frequency radiation generated by the switching power supply in the system from being induced through the cable to the surrounding components.
Unlike fuel-driven vehicles, the three-phase AC power that controls the motor of an electric vehicle becomes necessary. The sinusoidal voltage carrying energy is equivalent to square wave pulse signals of different frequencies. Since the high frequency pulses have steep edges, they generate harmonics with high energy emission into the surrounding area.
EMI problems can be completely solved by using appropriate shielding methods. In some cases to meet the different requirements of the shielding effect need to use a combination of different shielding types.

5. Marking
Because of the increased application risk associated with high voltages, various standards define that high-voltage cables must be visually distinguishable from ordinary automotive cables by specifying that the surface must be a bright orange color.

Of course, want to learn more about our electric vehicle product line? You can get more information in our high-voltage cable leaflet: https://www.omgevcable.com