In the transmission of electronic current from Power Plant to cities, high voltage wire and cable are used. But that is not the only place where high voltage cable is used. The electric machine and vehicles are highly in need of this product too. A high voltage cable (HV cable) is a cable used to transmit high voltage power. This cable consists of conductors and insulation and is suitable for underwater or underwater operation. This is in contrast to overhead lines, which are not insulated. Different types of high voltage wire have different uses in tools, ignition systems, and alternating current (AC) and direct current (DC). In all applications, the cable insulation will not be damaged by high voltage, ozone, or leakage from air discharge. Cable systems must prevent high-voltage conductors from coming into contact with other objects or persons, and must contain and control leakage currents. Cable connections and terminations must be designed to control pressure at high pressures to avoid insulation failure. High voltage cables typically have a metal shield over the insulation, grounded and designed to balance the dielectric stress in the insulation. High voltage cables can be of any length, relatively short cables are used in electrical appliances, longer cables are used as buried cables in buildings or industrial facilities or in power distribution, and the longest cables are usually used as submarine cables to transmit power. Cross section through 400kV cable, middle section flat conductor indicator, semiconductor and insulation, copper shielded conductor, aluminum sheath, and outer plastic sheath Like other cables, high voltage cables have one or more structural elements of conductors, insulation, and protective sheaths. High voltage cables differ from low voltage cables in that they have an extra inner layer in the insulation sheath to control the electric field around the conductors..
Cable
For circuits with voltages above 2000 volts between conductors, a conductive screen may be used around each insulated conductor. This is equal to the electrical load in the cable insulation. This technology was patented by Martin Hochstadter in 1916. Such shields are sometimes called Hochstadter shields. The shielding of each conductor of the cable is grounded at the end of the shield and in the slot. A tension cone is applied to the end of the shield. Distribution cables from 10 kV and above can be oil and paper insulated and run in rigid steel pipe, semi-rigid aluminum, or lead jacket. At higher voltages, the oil can be kept under pressure to prevent the formation of voids that can discharge the cable's insulation. Sebastian Ziani de Ferranti was the first to demonstrate in 1887 that carefully prepared and dried paper could form satisfactory cable insulation at 11,000 volts. Previously, paper-insulated wire and cable were used only for low-voltage telegraph and telephone circuits. An extruded lead jacket is required on the paper cable to ensure that the paper is completely dry. Vulcanized rubber was patented by Charles Goodyear in 1844, but was not used for cable insulation until the 1880s when it was used in lighting circuits. [1] Rubber insulated cable was used on an 11,000-volt circuit installed in 1897 for the Niagara Falls Power Generation Project. By 1895 paper insulated medium voltage cables were commercially available. During World War II, several types of synthetic rubber and polyethylene insulation were applied to cables. [2] Modern high-voltage cables use polymer or polyethylene insulation, including cross-linked polyethylene (XLPE).
High voltage wire for electric vehicles
The use of electric and hybrid vehicles (E&HV) is increasing as environmental awareness increases. Recycling, repair, and maintenance of high voltage (HV wire and cable) system of these vehicles outside the manufacturer and franchise dealer network is increasing. People in the auto repair and salvage industry are now more likely to encounter E&HVs and need to be aware of the additional dangers they may face when using these vehicles. They may also need to develop wider skills and knowledge and acquire specialist tools and equipment to work safely. The voltages in E&HVs (currently up to 650 volts direct current (dc)) are significantly higher than those used in other vehicles (12/24 volts direct current). In dry conditions, accidental contact with live parts with voltages higher than 110 VDC can be fatal. For E&HV, the direct high voltage between 60 and 1500 volts is called "high voltage". Although high voltage is defined differently in other industry sectors, the term is used in this guide. Battery systems may contain chemicals that can be harmful if released. They also store a lot of energy and can explode if not handled properly. E&HV design varies greatly from manufacturer to manufacturer. It is important to have information specific to the manufacturer and the vehicle being handled to determine the actions necessary to operate safely. Electric cars use batteries and high-capacity electric motors to power the vehicle. When the vehicle is not in use, the battery must be charged from the mains, although some energy can be recovered during braking. Hybrid cars typically have two energy sources, an internal combustion engine that uses diesel or gasoline as fuel, and a battery. Hybrid cars will automatically use both power sources and can use both at the same time. The internal combustion engine and energy recovered from the vehicle's braking system are used to charge the battery. Additional skills and training are required for people to use E&HV safely. The required level of competence varies widely and depends on the type of work you are expected to do. For example, someone who is in car sales or valet parking may just be aware of the additional risks. However, personnel involved in the repair and maintenance of vehicles may require a higher level of competence to operate these types of vehicles safely.
High voltage cable for electric vehicles
In electric vehicles, the propulsion power is provided by the electric engine which requires a powerful battery and energy source and high voltage electrical wire and cable for this specific use. Current battery systems for electric vehicles typically have an operating voltage of 200-600 volts. Its output current can reach 500A. Battery capacity directly affects the range of an electric vehicle, as well as charging efficiency and charging time. Currently, lithium-ion batteries dominate the global market. Limited by current battery technology, most electric vehicles use lithium-ion batteries. At the same time, in order to reduce the electromagnetic radiation generated by high-voltage components, the high-voltage system of electric vehicles adopts a shielding design. The battery management system (BMS), also known as the battery controller, is the core component of battery management and protection. Its function is to ensure safe and reliable use of the electric vehicle battery, control the charging and discharging of the battery pack, and report the basic parameters and fault diagnosis information to the vehicle control unit (VCU).
- Battery pack and battery management system (BMS)
Unlike conventional gasoline-powered vehicles, all-electric vehicles are powered solely by electricity, not an engine. Investment in battery electric vehicles is essential to reduce emissions in the long run. Therefore, the development of electric vehicles has been actively supported by the government and the state to avoid the catastrophic consequences of climate change and reduce environmental pollution.
Current battery systems for electric vehicles typically have an operating voltage of 200-600 volts. Its output current can reach 500A. Battery capacity directly affects the range of an electric vehicle, as well as charging efficiency and charging time. Currently, lithium-ion batteries dominate the global market. Limited by current battery technology, most electric vehicles use lithium-ion batteries. At the same time, in order to reduce the electromagnetic radiation generated by high-voltage components, the high-voltage system of electric vehicles adopts a shielding design. The battery management system (BMS), also known as the battery controller, is the core component of battery management and protection. Its function is to ensure safe and reliable use of the electric vehicle battery, control the charging and discharging of the battery pack, and report the basic parameters and fault diagnosis information to the vehicle control unit (VCU).
- Engine and Engine Control Unit (MCU)
The electric motor converts electrical energy from the battery into mechanical energy to drive the car. Compared to fuel vehicles that convert the chemical energy from fuel combustion into mechanical energy, it has a higher work efficiency (over 85%). Therefore, electric cars are more energy efficient than conventional vehicles. This can greatly reduce the waste of resources. A motor controller is a device that controls the energy transfer between the battery and the drive motor. Its main functions include controlling vehicle idle speed, vehicle forward (motor forward rotation), vehicle reverse (motor reverse rotation), DC/AC conversion, etc. It converts high voltage direct current to alternating current and realizes emotional control of the drive motor with other modules of the electric vehicle. 
- Power Distribution Unit (PDU)
The distribution box is a device that distributes high voltage power to the entire vehicle, similar to the electrical fuse box in the low voltage circuit system. It consists of many high-voltage relays and fuses and is equipped with related chips to realize signal communication and ensure the safety of high-voltage electricity consumption. It distributes high voltage battery power to high voltage electrical equipment such as motor controllers, drive motors, electric air conditioning compressors, PTC heaters and DC-DC converters. At the same time, the high voltage charging current from the AC or DC charging port is distributed to the battery to charge the battery pack.
- On-board Charge (OBC)
An OBC is a device that converts alternating current to direct current. Since the battery pack is a high voltage DC power source, the battery pack cannot store AC power directly when using AC power for charging. Therefore, an OBC unit is required to convert high voltage AC to DC to charge the battery.
- DC/DC
DC/DC is a device that converts high voltage direct current to low voltage direct current. Electric vehicles do not have an engine, and the entire vehicle's power source is no longer a generator and a battery, but a power battery pack and a battery. Since the electrical equipment of electric vehicles is usually powered by low voltage 12V or 24V, a DC/DC device is required to convert high voltage DC to low voltage DC to maintain the power consumption balance of the entire vehicle. Some DC/DCs are high voltage to high voltage conversions to facilitate 1) fast charging, 2) connection to standard charging stations, and 3) BMS reliability.
- Electric AC compressor
The electric scroll compressor for the electric vehicle air conditioner is mainly composed of a movable scroll, fixed scroll, bracket, anti-rotation mechanism, radial flexible mechanism, motor, and frequency conversion electronic control part. It is the heart of the electric vehicle air conditioning system. 
- PTC heater
The heat source for the traditional automotive HVAC system comes from the heat introduced into the engine after cooling the coolant, which is not found in new energy vehicles. This device is called a PTC heater. When the ambient temperature is low enough, the battery pack needs a certain amount of heat to function properly. At this point, the PTC heater is used to preheat the battery pack. Today, with the rapid research and development of electric compressor technology, new high-efficiency heat pumps are being developed and used to heat passenger cabins. Find out more about Goodson's EAC heat pump scroll compressors.
- High voltage cables
The high-voltage transmission cable function connects various components of the high-voltage system and acts as a medium for high-voltage power transmission. Unlike the low-voltage wiring harness, these wiring harnesses are equipped with high-voltage electricity, which greatly affects the stability of the vehicle's high-voltage system. The design and operation of electric vehicles should take into account and the safety of high-voltage power cables are also important.
0
0