EV CABLE,TESLA,BATTERY CABLE,UL62,TESLA,UL3644,UL3858,UL4476

Due to the rapid development of electric vehicle technology, the demand for higher voltage applications in high-power electric vehicles has grown significantly.

TA YU Technology proposes a cable application solution (AWM3644/AWM3858/AWM4476) to meet the design and requirements of electric vehicle cable configuration.

Silicone rubber and XLPE (Cross-Link PE) are used as high-voltage cable insulation materials.

Reference standard QC/T 1037-2016 "High-voltage cables for road vehicles": Standardize the requirements, test methods, and inspection regulations for high-voltage cables for road vehicles with a rated voltage below AC 1000 V / DC 1500 V. (The rated voltage below AC 1000 V / DC 1500 V is classified in GB/T 18384.1-2015 Voltage Class for Electric Vehicles - Class B).

The main points of QC/T 1037-2016 for cables are as follows:

1. The insulation inspection voltage is AC 900V /DC 1500V; the test voltage is 10KV.

2. The outer layer of the wire is limited to bright orange.

3. The minimum number of reciprocating times is 1000-1500 times.

4. The immersion time for chemical resistance is 10 seconds. The corrosive products such as gasoline and diesel are immersed for 240H after a single immersion, and the weak corrosive liquids such as coolant and glass water are immersed in 4 times, heat-aged for 3000H, and then rolled. Winding and insulation testing.

5. Flame Retardant is required for flame retardancy, and self-extinguishing time for extended combustion test is required to be less than 70 seconds.

Application

Type mm² (AWG)

Material

Description

Drive motor MCU

38 mm² (2AWG)

50 mm² (1/0AWG)

80 mm² (3/0AWG)

150℃ XLPE

150℃/200℃ Silicone

Thermosetting polymer

EMI Shield

Flexible

Air Conditioning System PDU

3.5 mm² (12AWG)

5.5 mm² (10AWG)

8 mm² (8AWG)

125℃ XLPE

150℃ Silicone

EMI Shield

Flexible

Battery- DC-DC

14 mm² (6AWG)

22 mm² (4AWG)

38 mm² (2AWG)

125℃ XLPE

150℃ Silicone

Flexible

DC-DC PDU

22 mm² (4AWG)

38 mm² (2AWG)

125℃ XLPE

150℃ Silicone

EMI Shield

Flexible

MCU-PDU

8 mm² (8AWG)

14 mm² (6AWG)

125℃ XLPE

150℃ Silicone

EMI Shield

Flexible

Battery

8 mm² (8AWG)

14 mm² (6AWG)

125℃ XLPE

150℃ Silicone

EMI Shield

Flexible

Battery-PDU

50 mm² (1/0AWG)

80 mm² (3/0AWG)

125℃ XLPE

150℃ Silicone

EMI Shield

Battery-BMS

20AWG Hook up Wire

200℃ FEP TEFLON

Smooth and high-temperature resistant

DC Charger

38 mm² (2AWG)

50 mm² (1/0AWG)

80 mm² (3/0AWG)

125℃ XLPE

150℃ Silicone

High temperature resistant

TESLA BATTERY PANEL ANALYSIS

Data Source: https://thenextavenue.com/2020/08/24/tesla-makes-the-frunk-of-the-model-3-smaller/

TESLA High Voltage Cable Specifications and QC/T Norms Description:

STANDARD	TESLA U.S.A (SAE J1654 )	QC/T 1037-2016
Sheath Color	ORANGE	ORANGE
Type	Withstand high voltage	Withstand high voltage
Rated Voltage	5000Vac,35min	Spark test, no breakdown AC 600 V/DC 900 V ,Spark tes 8 kV； AC 1000 V/DC 1500 V ,Spark tes 10 kV
Rated Temperature	-70～150℃	H Level：-40℃～250℃
Abrasion resistance	Sandpaper resistance 4-pound weight inches，10	Minimum reciprocating times 1000-1500 times
Chemical resistance	The hot salt solution, coolant, battery acid	Chemical resistance immersion time 10 seconds: Highly corrosive such as gasoline and diesel, heat aging for 240h after single immersion Weak corrosive liquids such as coolant, glass water, thermal aging 3000h.
Flame Retardant	Maximum time after burning the 70S	Self-extinguishing time is less than 30 seconds.