Performance optimization of high-voltage cables for automobiles

Perfect and sophisticated design and use of quality materials will result in expensive cable costs. Experience has shown that specific high voltage cables can often be tailored by optimizing cross-section, temperature requirements, flexibility and shielding effectiveness. Weight and cost savings can be demonstrated, and oversizing and components can be avoided to enhance the optimization of high-voltage cable performance.

Optimization of cross-sectional area and temperature class:

The selection of cables is mostly based on indicators such as ambient temperature and transmission current. The most important properties in this regard are the "cable cross section" and "the thermal class of the material used for the cable.

The voltage drop across the conductors is converted into the conductors of the high voltage cable which are heated by thermal energy. This heat can be partially transferred to the environment to reduce the conductor's operating temperature. A lower temperature gradient can transfer less heat. Cables with continuous load current can withstand the highest rated temperature. This temperature can lead to the ageing of the materials used.

Optimization for flexibility:

The space available for vehicle cable routing deserves careful consideration. The requirement for bending radius only in certain areas of the vehicle will lead to an increase in the flexibility requirement of the overall cable. If small changes can be made to the overall design, then avoiding the problem of tight bends makes a lot of sense.

Shielding effect optimization:

It is necessary to define the shielding effect of the cable within a certain range. The shielding effect without frequency information is not very useful, which can lead to solutions using oversized and expensive combined shielding, which is unnecessary from a technical point of view.


When choosing a cable, it is necessary to know clearly where the cable is used? For example, automotive high-voltage cables are used to connect controllers, motors, batteries, etc. Of course, the appropriate specifications and models are also very important. But no matter what you choose, you need a high-voltage cable with high performance requirements. For more EV HV cable specifications, please visit: https://www.omgevcable.com/

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