Conventional logic may assume that the thicker the high-voltage wire harness of an electric vehicle, the more solid the material used, and the greater the available power, while high-voltage wire harnesses with smaller wire diameters are cutting corners. In fact, the required diameter of high-voltage wire harness depends on its specific application scenario.
There is more than one high-voltage wire harness used in new energy vehicles, and high-voltage wire harnesses are required to connect components such as fast charging ports, power distribution units, battery packs, and power distribution units. The wire diameter of the high-voltage harness connected between different components also varies. Generally speaking, the high-voltage harness connected to the motor is thicker.
Different power requirements and assembly positions result in varying diameters of high-voltage wiring harnesses. So, some people may say that using thicker wiring harnesses on new energy vehicles is not feasible? Isn’t this safer?
Just as we don’t connect an air conditioning cable to a phone charger, there are strict regulations on the weight and space of parts in cars. The thicker the wire harness, the larger the bending radius, which is not conducive to installation in narrow spaces of cars, and the price is also higher, so the necessity is not high.
As a provider of high-voltage wiring harnesses, let me introduce the special structure of high-voltage wiring harnesses for new energy vehicles:
High voltage wiring harness cables for vehicles are composed of a large amount of copper wire, which is beneficial for enhancing conductivity, as high-voltage wiring harnesses mainly play a role in transmitting electrical energy. This design has many benefits. The main high-voltage wire harness has a large cross-sectional area, which is 5-10 times thicker than household wires. It has strong rigidity and is difficult to bend. It is not only difficult to layout inside the car, but also more likely to pierce into the cockpit after a collision, increasing safety risks. Considering factors such as strength, toughness, and safety, multi-core wires are also a better choice.
Automotive wiring harnesses are mainly selected based on current and voltage requirements, as well as application scenarios, and thicker wires are not necessarily better. The use of high-voltage wiring harnesses requires strict conditions, higher standards, and more details to be considered in design to ensure safer and more durable use.