Discussion on Automobile High Voltage Cable
China [CN] Any electrical cables used on the vehicle should be insulated to prevent false contacts and short circuits. Cables are mostly made of copper wire because copper has low electrical resistance and is more malleable.
The insulating material is usually made of polyvinyl chloride (PCV). High-voltage wiring harnesses require greater insulation to prevent voltage leakage, because if leakage occurs, the risk of human injury from accidental contact is very high. Inside the vehicle, stickers with various symbols are often affixed to high-voltage wiring harnesses, along with bright orange insulation to warn of hazards.
If the wiring harness needs to transmit high power, it must carry large currents. We know that power is equal to voltage multiplied by current (P = IV), and current I=P/V. We assume that the total voltage of the power battery is 250 V. If the instantaneous power transmitted by the high-voltage harness is 20 kW, then the current transmitted at this time is 20,000 / 250 = 80 A. Under full throttle acceleration this figure is even higher, eg 80 kW requires 320 A. Therefore, high-voltage wiring harnesses are generally designed to be thick (copper cables) and thick (insulating materials).
(OMG) high voltage cable related products recommended: https://www.omgevcable.com/ev-cables/ev-high-voltage-cables.html
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