Design of manufacturing processes for automotive high-voltage cables

Standard products and products with custom requirements can be difficult to define. The following description of the manufacturing process for high-voltage cables intended for automotive applications addresses basic design ideas.


1. Conductor design

The flexibility of high voltage cables is mostly determined by the design of the conductor. This is why high-voltage cables use special conductors with a large number of very small diameter monofilaments. A certain number of monofilaments are first bundled and then concentrically rewound to form the flexible conductor needed for high voltage cables.

An additional benefit of a larger number of strands is better resistance to bending. The shorter pitch of the stranded wire also improves the bending life of the high voltage cable. Customers can use the cable according to the fixed specification size requirements.


2. Insulation material

The choice of insulation material is mainly based on heat resistance requirements and mechanical strength. Compared to standard battery cables, softer materials can be reasonably selected to keep the specially designed stranded conductors flexible.


3. Cable formation

Cables when multi-core usually need to be stranded cores. In order to compensate for the deformation caused by stranding the cores of high-voltage cables, special equipment for so-called untwisting is required. In this process, a special stranding machine is equipped with a payoff reel that rotates in the opposite direction to the stranding direction. This is necessary to prevent the deformation of the cable tension.

Depending on the construction of the cable, a filler is usually used to ensure a high degree of concentricity of the shielded cable and ultimately achieve a satisfactory high-voltage cable. The use of wrapping tape on the stranded cable core can maintain the flexibility of the cable.


4. Shielding

Due to EMC (electromagnetic compatibility) requirements, multiple copper wires are used to form a braided shield. Tinned copper wire can make it stronger against environmental influences such as oxidation. Using fine copper wire can maintain the flexibility of the design.

The shielding needs to have a coverage of 90% or more to overcome the EMI problems described earlier.

The shielding effectiveness of the different needs, woven shielding can be combined with various other shielding, such as aluminum plastic in line with the film. The outside of the shield can be wrapped around a layer of non-woven fabric to ensure easy peeling off of the sheath during the assembly process.


5. Sheathing

As with the insulation of the core, the sheath material is selected according to the thermal and mechanical requirements. The choice of softer materials benefits from flexibility, which can result in lower wear resistance in high voltage cables. According to the relevant specifications, the extruded jacket should be a bright orange color, and special markings warning of high voltage can also be added according to the regulations.


OMG cable related product information recommended: https ://www.omgevcable.com/ddqcqddl/97.html

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