The high-voltage components are mainly three electric parts, including power battery, driving motor and high-voltage distribution box (PDU) of electric control system. For batteries, there are DC contactors, high-voltage relays, precharge resistors, etc. for motors, there are stators, rotors, current sensors, AC contactors, etc. for electric control systems, there are on-board chargers, PTC, electric compressors, high-voltage line contacts, OBC / DC, DC two in one controllers, etc.



Among them, the high-voltage suitable distribution box used in new energy vehicles (pure electric) includes copper plate, circuit breaker, air switch, internal contactor, soft start, frequency conversion container, transformer, contactor, relay, knife fuse switch, surge protector, transformer, ammeter, voltmeter, transfer switch, etc.



New energy vehicles usually operate under high-power power power, with voltage up to 700V (DC) and current up to 400A, which poses a great challenge to the design of high-voltage distribution system and the selection of high-voltage parts. Considering the complexity and cost of vehicle space, vehicle architecture, the centralized high-voltage electrical system architecture is widely used in the industry.


After the high-voltage power supply directly enters the high-voltage distribution box, it is distributed to the high-voltage electrical products of the system according to the needs of the system. It has high requirements on how to ensure the safety of the whole high-voltage system and its electrical equipment, system insulation, electromagnetic interference, shielding, sealing and vibration resistance. However, at present, most of the high-voltage distribution boxes on the market follow the design concept of industrial high-voltage distribution box, and its safety, reliability and durability can not meet the requirements of automobile working conditions. For example, for high-power loads, such as motor inverter and voltage converter (DC / DC), precharge processing and condition monitoring are required. The traditional electrical circuit is difficult to achieve effective monitoring, which is very easy to cause the damage of high-voltage switch parts, such as terminal adhesion and so on. The industry often adopts products with relatively high electrical parameters to solve this problem, but the volume and cost are not satisfactory.


As for the internal parts of new energy vehicles (pure electric), the drive motor controller (commonly known as "MCU") converts high-voltage DC into AC, and interacts with other modules on the whole vehicle to realize the effective control of the drive motor. Motor energy recovery function, inverter, interlock, communication, etc. drive the motor to drive the car. Compared with the engine of traditional fuel vehicles, the chemical energy of fuel combustion is different from that of mechanical energy, and its working efficiency will be higher, which can reach more than 80%. Therefore, compared with traditional vehicles, its energy utilization rate is higher, which can reduce the waste of resources.


High voltage distribution box (commonly known as "PDU"), which is a power distribution device for high-voltage power of the whole vehicle, and then transmitted to the distribution device through high-voltage cable. It is mainly used to distribute high-voltage power to each actuator drive, which is similar to the electrical fuse box in low-voltage circuit system. High voltage fuse box PDU (power distribution unit) is composed of many high voltage relays and high voltage fuses. Coordinate the function conversion and energy distribution of high-voltage accessories such as drive motor control system, battery management system, charging management system, DC / DC, electric air conditioning, electric power steering, braking system, etc. The high-voltage distribution unit can also realize the safety protection functions of short-circuit overload, fast power-off protection, anti leakage protection and so on.


DC / DC converter. In new energy vehicles, DC / DC is a device that converts high-voltage DC into low-voltage DC. There is no engine on new energy vehicles, and the source of power for the whole vehicle is no longer generators and batteries, but power batteries and batteries. Since the rated voltage of electrical appliances for the whole vehicle is low voltage, DC / DC device is required to convert high-voltage DC power into low-voltage DC power, so as to maintain the power balance of the whole vehicle.


On board charger (commonly known as "OBC") is a device that converts alternating current into direct current. Because the power battery is a high-voltage DC power supply, when the AC is used for charging, the AC cannot be directly stored by the battery pack. Therefore, the power conversion device OBC is required to convert the high-voltage AC to high-voltage DC, so as to charge and store the power battery.


However, as the high-voltage cable connecting the internal parts of the car, it plays an important role in transmitting power. The automobile high-voltage cable is a kind of "conductor" with "insulation" device, which transmits electric energy through the ignition coil for the ignition of the spark plug, so as to make the engine work. Its structure is not complex. A layer of high-strength insulator is wrapped outside the internal metal conductor through the production process. It can have good insulation, internal transmission and conductivity at high and low temperature. Cables with the following characteristics in Omega cable products. Omega automobile high voltage cable adopts thermosetting material, high temperature resistance, softness, shielding structure and tear resistance.


To learn more about EV cable and EV Charging cable, please visit OMG's official website: https://www.omgevcable.com/