In the last couple of years, high voltage colored wires and cables have been used for the electrical systems and main boards of vehicles and cars, the Mitsubishi Lancer being a famous example.
The 2007 model year introduced a major change in one of the fundamentals of gasoline-electric hybrid vehicles.
From the perspective of fire and rescue personnel, our experience with hybrid vehicles tells us that these vehicles have high voltage electrical systems.
It consists of a high-voltage battery somewhere in the back of the car, an electric motor somewhere in the engine compartment, and a bunch of heavy cables that connect the two together.
We also know from the first hybrid car that was released in the US in 2000 that the high voltage cables and plugs in a hybrid car were orange “traffic cones”.
This is a great thing. If the pressure is high, it is orange. Well, with the current model of hybrids, a lot of that has changed.
This Liberty University column is designed to show an image of the engine compartment of a 2007 gasoline-electric hybrid vehicle. Teaching tips are clear by looking at these pictures.
Manufacturers no longer identify high voltage hybrid cables and connectors by orange color only. High voltage power lines are now color coded orange, light blue and even yellow. Some hybrid cars use two different colors of high voltage electrical systems in one car! All orange cables on gas-electric hybrids are high voltage.
However, not all high voltage cables in a hybrid are orange! Lift the hood and see for yourself.
Our main point 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 in a hybrid car are high voltage, but not all high voltage cables in a hybrid car are orange!
After the mass production of electric vehicles, the use of high voltage cables and wires increased incredibly.
Any high voltage (HV) electrical system requires specialized personnel training, protective equipment and precautions to ensure the safety of those working on the ground. In this article, we cover the basic safety tips you should be aware of when working on a high-voltage electric vehicle.
All EV professionals as well as employers should know these basics.
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.
The voltage range is different depending on the car class. Two and three wheel electric motors are available in the market from 24V to 72V depending on the power and acceleration required by the vehicle. However, for 2W and 3W, voltage up to 60V is preferred to keep the certification process simpler and cheaper. 48 volt systems are suitable for 2 and 3 watt power.
For 4W, the range is usually between 300V and 500V, while currently there are 800V to 1200V power 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 danger of working on a high voltage installation is “electrical shock”, which in some cases can be fatal.
High voltage cable for board Mitsubishi lancer
As we mentioned for example Mitsubishi Lancer, the high voltage wire and cable can not only be used in the car panel, but also used as a spark to burn fuel.
The ignition cable must show high strength because it uses a very high voltage to transfer instantaneous current, so with the help of this cable, the current can be transferred with excellent quality from the power source to the combustion chamber.
Therefore, its valuable properties are pointed out and its wide application in areas that require strength and resistance to high temperature is depicted.
Ignition cables are made in the best possible way using modern technology and modern industrial machines.
Therefore, it can be unique and strong in all types of wires and cables suitable for industrial areas. High thermal 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 to find a variety of ignition cables in the aviation, rail and power plant industries. Of course, nowadays most power plants, steel industries and lighting systems have been enjoying the valuable benefits of these cables for years.
In addition, high temperature circuits 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 parts, 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, the accessories of the spark plug, such as wire, wire and cable of the spark plug, etc., determine the normal work of the spark plug.
When the spark plug is ignited to explode the air and fuel in the cylinder, the spark plug wire and cable provide the power it needs.
The vibration and high temperature of the engine requires the replacement of the wire and cable of the spark plug to prevent the voltage drop from reaching the spark plug, which, if neglected, leads to wasted energy and reduced engine efficiency.
With these explanations, it can be said that the most important advantage of the spark plug cable is keeping the technical system healthy and providing perfect engine performance.
Although today’s modern car systems often mount wires and coils directly to the spark plug to prevent voltage drop and wasted energy, the coil responsible for raising the voltage to the level required by the spark plug is still what older cars used for optimal performance. they need. They depend on its wire and cable.
All electric vehicles run high voltage (HV) wires through orange tubes to connect the HV components in the drive system.
Risk of electric shock from high voltage cables and high voltage parts if not used correctly.
These include DC:DC converters, internal chargers, AC compressors and charging ports. It also includes a lithium battery, which we’ll take a closer look at next time.
High-voltage cables and devices represent electric vehicles that operate at 400 V or higher. Newer models can eventually operate up to 1000 volts.
In all incidents involving electric vehicles, cables and high-voltage parts present a risk of electrocution to emergency personnel. The orange cable must not be cut or tampered with.
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 should be followed carefully. See the resource page for links.
High voltage wire for board Mitsubishi lancer
Mitsubishi Lancer was a famous model and a good example of using high voltage cable and wire on the car board.
But with the development of the automobile industry, the use of HV cable in electric cars and vehicles became bold.
Electric car sales are slowly starting to grow in Europe as major brands such as Volkswagen, BMW, Fiat, Opel and Hyundai begin to offer battery models.
But while many governments are pushing to ban sales of new petrol and diesel cars over the next 20 years in favor of pure electric vehicles, existing battery-powered car technology limits their range and makes them take longer to refuel than their electric counterparts. takes. .
Competitors of internal combustion engines. That and their higher prices still prevent them from becoming mainstream anytime soon.
For many industry observers, the development of the electric system in battery-powered vehicles from the current industry standard of 400 volts to 800 volts could be the breakthrough that will eventually take electric vehicles to a higher level and better compete with and eventually replace combustion. to be vehicles.
This is a necessary transition as Europe works to reduce vehicle emissions and fight climate change.Professor Peter Wells, from Cardiff University’s Center for Automotive Industry Research, said: “As with ‘advanced’ technology options in the automotive industry, we can expect them to move quickly to the mass market due to competitive pressures. In some cases, manufacturing companies have developed the ability to transition from 400V to 800V due to cost reduction 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 Taycan all-electric sports car launched last year.
For Otmar Bitsche, director of electric vehicles in the automaker’s research and development 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. believe. .
By using a fast charger that can work up to 270 kW, the charging time can be significantly reduced.
If the charger supplies 800 volts and at least 300 amps, the Taycan can be charged from 5 to 80 percent in 22.5 minutes.
400V chargers usually only provide 50kW. Bitsche explains that the same charging capacity takes 90 minutes.
The automaker, which introduced an 800-volt electric system for the first time commercially, claims its sedan coupe will travel 420 kilometers on a single charge.
Although compared to the figures achieved by competitors using 400V systems (such as Jaguar’s I-Pace, which can travel 354 km on a single charge), using an 800V system greatly increases the range. From their electric cars
High voltage wire for Mitsubishi Lancer board
One advantage is that the 800-volt electrical system allows for more power to be stored, which is usually lost due to heat generated during charging.
A higher voltage system allows less current to be used when charging the battery, which reduces overheating and allows for better energy 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. Copper reduction is one of them.
Electric motors are much simpler in construction than internal combustion engines, and at their heart is a rotor that spins in response to the rotating magnetic field produced by the battery.
To achieve this, electrical systems typically use four times the copper used in internal combustion engines. Using a higher voltage system can reduce the amount of copper used in the motor.
“Higher voltage means less current, and less current means less copper in the car,” said Michael Burgard, senior project manager at German company AVL.
Less copper means less weight, and that’s what we’re looking 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 also has the added advantage 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 its 400-volt counterpart. That is, at this speed, instead of high torque, they convert electrical energy into mechanical energy.
“In general, engine size is defined by torque capacity, meaning that removing torque from the equation makes the engine smaller,” Bitsche said.
In fact, small high-speed motors can weigh up to 25 kg, which reduces the overall weight of the vehicle and allows it to go further on a single charge.
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