There are various sizes of high-voltage cables, including 4mm², 10mm², 16mm², 25mm², 35mm², 50mm², 70mm² and so on. According to the formula W=I²Rt, the resistance is inversely proportional to the cross-sectional area of the conductor. That is, the thicker the conductor, the lower its resistivity and the less heat it generates when passing the same current. If this is the case, why are there so many specification options? In fact, in the actual car application environment, the weight of each part in the car and the wiring space are strictly controlled. And the wire harness and bending radius is proportional to the bending radius of the cable is too thick will be larger, and not the thicker the wire the safer. In addition, thicker cables are more expensive, if there is no reasonable choice will increase the cost excessively.

The selection of high voltage cables for electric vehicles can be based on the following elements: high voltage cables for electric vehicles need to be able to withstand the current load required by the electric vehicle system. In the case of higher current loads, thicker cables are usually required to ensure the stability and safety of current transmission. Secondly, in the case of wiring that requires longer cables, the longer cables will have higher resistance and power loss, so it may be necessary to choose thicker cables to reduce the loss. Thirdly, the high temperature environment will have an impact on the conductive and insulating properties of the cable. In high-temperature environments, choosing thicker cables can reduce the temperature rise of the cables and improve their reliability and lifetime. Further, electric vehicle high-voltage cables usually need to be bent in various parts of the vehicle, so it is necessary to select cables with sufficient flexibility. Taking the above factors into consideration, choosing cables with appropriate specifications can ensure the normal operation and safety of the electric vehicle system.

The thickness of electric vehicle cables should be selected in conjunction with the actual needs and wiring arrangements. Generally, thick high-voltage cables are used for the power distribution unit, battery pack ESS, motor and PEB; thin high-voltage cables are used for the charger OBC, battery pack ESS, and the power distribution unit, and thin high-voltage cables have positive and negative poles within the same high-voltage cable.

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