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Nowadays, for electric vehicles, increasing the cruising range to make long-range electric vehicles is the main development path. When the cost of batteries drops and the combined range reaches 500-600 kilometers, the main contradiction of electric vehicles changes from range anxiety to charging anxiety. Improving the charging power of electric vehicles mainly includes several core elements. The following is the way to analyze the reasons: First: increase the current. If we keep the other components the same and choose the path to increase the current, the main limitation is the heat loss due to the high current, which can make a big difference in the overall design. High currents in a circuit create high heat losses, as the resistance of all components (connectors, cables, electrical connections to batteries, bus bars, etc.) inevitably heats up. If the battery overheats during charging, these heat losses need to be taken into account when designing and sizing conductive elements to avoid problems such as overloading, overheating, or controlled derating of the charging current. Second: increase the voltage. Since the increase of the above current is limited, the current limiting current is generally defined as 500A, and the achievable power is around 200kW (Tesla designed more than 600A at 400V as an attempt), increasing the voltage to switch the 400V system to 800V becomes an option. This is a systematic improvement of all electrical components. The core switchgear and other parts have changed. At current costs, these modules developed to the 800V specification are relatively expensive. Taking the main inverter as an example, the cost of the core SiC module is about 4 times that of the original IGBT module. Let's take a closer look at some of the issues that need to be considered in a path that can be reached either way. Since several methods have the same requirements for the cell, we list the cell problem at the end, focusing on the electrical connection and thermal management inside. |
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The difference between automobile high-voltage wiring harness and electric vehicle charging cable: In electric vehicles, electric vehicle high-voltage cables are used to connect the charging port and the battery, inside the battery, and between the battery and the engine. Components, as well as battery storage devices, as a vehicle for power transmission inside the vehicle.
The difference between automotive high-voltage cables and charging cables is divided into 10 aspects: different laying, different heat resistance, different EMI requirements, different protection measures, different physical performance requirements, different size requirements, different color requirements, and number of cable cores Different, different international standards, etc. Protective measures: The internal environment of the car is complex and harsh, and there are necessary protective measures around the high-voltage cable of the car; the charging cable has no protective measures and can withstand various shocks and ultraviolet radiation. Physical performance requirements: Automobile high-voltage cables need to meet the wear-resistant requirements of automobiles; charging cables should meet the anti-extrusion requirements of mobile cables. Chemical resistance: Automotive high-voltage cables need to withstand various liquids that can be contacted on the car; charging cables need to withstand various liquids from the living environment outside the car. Size requirements: The automotive high-voltage cable is limited by space and has strict size requirements. The smaller the size, the better; the charging cable has no size limit, and can be made thicker and larger. Color requirements: Internationally, the color of automobile high-voltage cables is orange; however, there is no requirement for the color of charging cables. Among them, OMG charging cable features for products with more specifications and models that meet the requirements, For more information about on EV cable of new energy vehicle and electric vehicle charging cable products, please browse the OMG official website and contact us : https ://www.omgevcable.com/ddqcqddl/97.html |
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What are the common causes of cable aging? The most direct cause of wire and cable aging failure is insulation breakdown and breakdown. Many factors can reduce the sensitivity of insulation. According to the actual operation experience, it can be summarized into the following situations. 1) Reasons for cable aging: external force damage. From the analysis of the operation situation in recent years, especially in Haipudong, where the economy is developing rapidly, a considerable number of cable faults are now caused by mechanical damage. For example: when the cable is laid and installed, the construction is not standardized, which is easy to cause mechanical damage; when the civil construction is carried out on the directly buried cable, it is also easy to damage the wiring. l Sometimes if the damage is not serious, it will take months or even years for the damaged part to completely decompose and cause a failure. Sometimes serious damage may lead to short circuit failure, which directly affects the power plant and the safe production of power plant. 2) Reasons for cable aging: The insulation is damp. This is also common and usually occurs at cable joints in direct burial or drains. For example, substandard cable splices and prefabricated splices in wet climates can allow water or steam to enter the splices. Over time, water branches will form under the action of the electric field, gradually destroying the insulation strength of the cable and causing failure. 3) Reasons for cable aging: chemical corrosion. Cables buried directly in areas with acid and alkali effects tend to corrode the armor, lead or outer sheath of the cable. The protective layer is subjected to chemical corrosion or electrolytic corrosion for a long time, which makes the protective layer fail and the insulation is reduced. Cable failure. Chemical: Corrosion of cell cables is quite severe 4) Reasons for cable aging: long-term overload operation. In overload operation, due to the thermal effect of the current, the conductor inevitably heats up when the load current passes through the cable. At the same time, the skin effect of the electric charge, the eddy current loss of the steel armor, and the dielectric loss will also generate additional heat, which will increase the temperature of the cable. During long-term overload operation, excessive temperature will accelerate insulation aging and damage the insulation. Especially in hot summer, the temperature rise of the cable often causes the weak insulation of the cable to be broken down first, so in summer, there are especially many cable failures. 5) Reasons for cable aging: cable connector failure. The cable joint is the weakest link in the cable line, and the cable joint failure caused by the direct failure of personnel (poor construction) often occurs. In the process of making cable joints, if the original mesh of the joint is not under pressure or insufficiently heated, the insulation of the cable head will be reduced, resulting in accidents. 6) Reasons for cable aging: environment and temperature. The external environment and heat source of the cable can also cause the cable temperature to be too high, insulation breakdown, and even explosion and fire. For more information on EV cable for new energy vehicles and charging cables for electric vehicles, please visit OMG’s official website: https://www.omgevcable.com |
