In the past couple of years, high voltage coded color wire and cable were used popularly for electric systems and the main board of the vehicles and cars, Mitsubishi lancer is a famous example of this. The 2007 model year made a big change to one of the fundamentals of a gasoline-electric hybrid car. From a fire and rescue personnel perspective, our experience with hybrid vehicles tells us that these vehicles have high voltage electrical systems. This includes a high-voltage battery somewhere in the back of the vehicle, an electric motor somewhere in the engine compartment, and a bundle of heavy-duty cables connecting the two together. 
We also know from the first hybrid car launched in the US in 2000 that the high voltage cables and plugs in a hybrid car were orange "traffic cones". It's a great thing. If it's high pressure, it's orange. Well, with the current model year of hybrids, much of that has changed. This Liberty University pillar is designed to be a pictorial representation of the engine compartment of a specific 2007 model year gasoline-electric hybrid vehicle. Teaching points will become clear as you look at these pictures. Manufacturers no longer identify high-voltage hybrid cables and connectors only with orange. High voltage power lines are now color coded in orange, light blue, and even yellow. Some hybrid cars use two different colors of high voltage electrical systems in the same vehicle! All orange cables on gas-electric hybrids are high voltage. However, not all high voltage cables on a hybrid are orange! Lift the hood and see for yourself. Our bottom line for hybrid vehicle crash safety is for responders to recognize that they are dealing with a hybrid vehicle in the first place. 
Remember that all orange cables on a hybrid car are high voltage, but not all high voltage cables on a hybrid car are orange! After the mass production of electric vehicles, the application of high voltage cables and wires incredibly increased. Any high voltage (HV) electrical system requires specialized personnel training, protective equipment, and precautions to ensure the safety of those working on the floor. In this article, we cover the basic safety-related things you need to be aware of when working on a high-voltage electric vehicle. All EV professionals, as well as employers, should know these basic principles. In the automotive industry, voltages above 60 V DC are referred to as high voltage. At this level, the need for contact protection becomes mandatory. Voltage ranges vary by vehicle class. Electric two- and three-wheel motors are available in the market from 24V to 72V, depending on the power and acceleration requirements of the vehicle. However, for 2Ws and 3Ws, voltages up to 60V are preferred to keep the certification process simpler and cheaper. 48V systems are best suited for electric 2W and 3W. For electric 4W, the range is usually between 300 and 500 V, while currently there are 800 V to 1200 V electric buses in the Indian market. Any component connected to the HV battery pack is a high voltage component.
- Traction battery pack
- DC-AC inverter
- electric motor
- DC-DC converter
- Car charger
- compressor
- PTC heater
- Distributors
The risk of working on a high voltage installation is "electric shock", which in some cases can be fatal. 
High voltage cable for board Mitsubishi lancer
As we mentioned the Mitsubishi lancer as an example, the high voltage wire and cable not only can be used in a vehicle board but also it is used as an ignitor to burn the fuel. The ignition cable must show high power because it uses very high voltage to transfer instantaneous current, so with the help of this cable, current can be transferred from the power source to the combustion chamber with excellent quality. Therefore, its valuable properties are mentioned and its wide application in areas requiring strength and high temperature resistance is illustrated. Ignition cables are manufactured in the best possible way using modern technology and modern industrial machinery. Therefore, it can be unique and strong in the types of wires and cables suitable for industrial areas. High heat resistance and its use in combustion systems is the first and most important advantage of these cables. Of course, resistance to high voltage current is another feature of this cable. In addition to these, finally, the ability to withstand high-frequency resistance makes the ignition cable a stable and durable element. 
With the above advantages, it is not surprising that we find different types of ignition cables in the aviation, railway and power plant industries. Of course, most power plants, steel manufacturing industries and lighting systems today have enjoyed the valuable benefits of these cables for many years. In addition, circuits for high temperature and automotive equipment, diesel engines, etc. also have an urgent need for these cables. The technical system in a car has many components, and the movement of the car comes from their cooperation. Among these components, the spark plug plays a key role and the perfect performance of the engine depends on this small but effective component. At the same time, spark plug accessories such as wires, spark plug wires and cables, etc., determine the normal work of the spark plug. When the spark plug is ignited to explode the air and gasoline in the cylinder, the spark plug wire and cable will provide the power it needs. Vibrations and the high temperature of the engine require replacement of the spark plug wire and cable to prevent a voltage drop from reaching the spark plug, which, if ignored, can lead to wasted energy and reduced engine efficiency. 
With these explanations, it can be said that the most important benefit of the spark plug cable is to keep the technical system healthy and provide the perfect performance of the engine. Although today's modern automotive systems often mount wires and coils directly to the spark plug to prevent voltage drops and wasted energy, the coil responsible for raising the voltage to the level required by the spark plug is still what old cars need for optimal performance. They depend on its wires and cables. All electric vehicles run high voltage (HV) wires through orange tubes to connect HV components in the drive system. Risk of electric shock from high voltage cables and high voltage components if not handled properly. These include DC:DC converters, onboard chargers, AC compressors and charging ports. It also includes a lithium-powered battery, which we'll take a closer look at next time. High voltage cables and devices represent electric vehicles running at 400V or higher. Newer models can eventually run at up to 1000V. In all accidents involving electric vehicles, high-voltage cables and components pose a risk of electric shock to emergency personnel. The orange cable must not be cut or handled. Emergency personnel should not attempt to access the HV traction battery with cutting or bare tools If the orange high voltage cable is damaged or exposed in an emergency, the vehicle manufacturer's emergency response instructions must be followed closely; see resource page for links. 
High voltage wire for board Mitsubishi lancer
The Mitsubishi lancer was a famous model and a good example of the use of high voltage cable and wire on the board of a vehicle. But as the car industry developed, the application of HV cable in electric cars and vehicles became bold. Electric car sales are slowly starting to grow in Europe as mainstream brands such as Volkswagen, BMW, Fiat, Opel, and Hyundai begin rolling out battery-powered models. But while many governments are pushing to ban the sale of new petrol and diesel cars over the next 20 years in favor of pure electric vehicles, existing battery car technology limits their range, making them take longer to refuel than their electric counterparts colleagues who take longer. Competitors of internal combustion engines. This and their higher prices continue to hinder their chances of becoming mainstream any time soon. For many industry watchers, the development to take the electrical system in battery-powered cars from the current industry standard of 400 volts to 800 volts could be the breakthrough that will finally take electric cars to the next level and better compete with and ultimately replace combustion vehicles. This is a necessary transition as Europe works to reduce vehicle emissions and combat climate change. Professor Peter Wells, from Cardiff University's Center for Automotive Industry Research, said: "As is the case with 'advanced' technology options in the automotive industry, we can expect them to move rapidly to the mass market due to competitive pressures. In some cases, manufacturing companies have developed the ability to migrate from 400 volts to 800 volts due to falling costs and the need for such systems to be competitive." 
Companies that have already adopted the technology include Volkswagen Group sports car brand Porsche, which installed the 800-volt system in the all-electric Taycan sports car launched last year. For Otmar Bitsche, director of electric vehicles in the automaker's R&D department, the reasons for choosing a higher power unit are clear: "Lighter weight, higher efficiency and faster charging" are the main advantages of an 800-volt system, he said. Believe. . By using a fast charger that can operate with up to 270 kW, the charging time can be significantly reduced. "If the charger provides 800 volts and at least 300A, the Taycan can charge from 5% to 80% in 22.5 minutes. 400V chargers typically only provide 50kW. The same charging capacity takes 90 minutes," explains Bitsche. The automaker, the first to introduce an 800-volt electric system commercially, claims a range of 420 kilometers on a charge for its four-door coupe-style sedan. Although not much higher than the figures achieved by competitors using 400-volt systems (such as Jaguar's I-Pace, which can drive 354 kilometers on a single charge), the use of an 800-volt system in greatly the possibility of increasing the range of their electric cars. 
One of the advantages is that the 800-volt electrical system allows for greater power retention, which is normally lost due to heat generated during charging. A higher voltage system allows lower current to be used when charging the battery, which reduces overheating and allows for better power storage in the system. This power can be used for longer driving distances. High voltage systems also offer a number of important weight and weight savings. The reduction of copper is one of them. Electric motors are structurally much simpler than internal combustion engines, and at their heart they have a rotor that turns in response to the rotating magnetic field produced by the battery. To achieve this, electrical systems typically use four times the amount of copper used in internal combustion engines. Using a higher voltage system can reduce the amount of copper used in the motor. Michael Burghardt, senior project manager at German company AVL, said: "Higher voltage means less current, and less current means less copper in the car. Less copper means less weight, and that's what we're going for. Target." Burghardt is collaborating with the EU research project Drivemode, which seeks to develop an efficient, compact and modular drive system for fully electric vehicles that uses the vehicle's stored energy more efficiently through a higher voltage power system. In addition to reducing the weight of the electric motor, the 800-volt system has the added benefit of reducing its mass. 
They have better power density, as the higher voltage allows the motor to run at 20,000 rpm, more than double that of its 400-volt sibling. This means that they convert electrical energy into mechanical energy at this speed instead of high torque. "In general, engine size is defined by torque capacity," Bitsche said, meaning that removing torque from the equation allows the engine to be smaller. In fact, small high-speed motors can weigh as little as 25 kg, reducing the overall weight of the vehicle and allowing it to go further on a single charge.