As one of the most important means of transportation for our daily travel, the automobile is widely used. However, as the performance requirements of the internal parts of the automobile become higher and higher, the requirements for the cables and wires used in it also become higher, such as automotive cables/automotive wiring harnesses. Do you know what are the classifications and characteristics of automotive cable? How to choose the right automotive cable?
Automotive cables are a key component of the automotive electrical system, responsible for transmitting power, signals and data between various components of the vehicle. With the development of automotive technology, especially the rise of new energy vehicles and intelligent networked vehicles, the importance of automotive cables has become increasingly prominent.
Automotive cables are a kind of connecting wire inside the car, which can be mainly used for current transmission such as batteries, instruments, and lights. Due to the particularity of the automotive industry, the manufacturing process of automotive cables is also more special than other ordinary wires. In most cases, automotive cables are required to be cold-resistant and high-temperature resistant.
Classification of automotive cables
Automotive cables are classified into high-voltage cables and low-voltage cables according to voltage, both of which are processed with copper multi-core soft wires. The cross-sectional area of the wire is mainly selected according to its working current. For some electrical appliances with very small current, in order to ensure that the wires have a certain mechanical strength, the wire cross-sectional area shall not be less than 0.5mm2/2.5mm2. Since the starter works in a short period of time, in order to ensure that the starter can generate enough power when it works normally, the voltage drop generated by every 100A of current on the line must not exceed 0.1v-0.15v, so the wire cross-sectional area used is larger. The high-voltage wire of the car has a very high withstand voltage, which should generally be above 15kv, so its cross-sectional area is very small (because the current is very small), about 1.5mm2, and the thickness of the insulation layer is much thicker than that of the low-voltage wire. Rubber insulation is mostly used, and there is a varnished cotton braided package.
Automotive cables can be divided into many types according to their functions and use environments, including but not limited to:
Low-voltage wires: used to transmit low-voltage power of 12V or 24V, including ordinary wires, starting cables and grounding cables.
High-voltage wires: used to transmit hundreds of volts of power in new energy vehicles, and used for connection between battery packs and motors.
Signal lines: transmit various signals, such as sensor data, control signals, etc.
Data line: used for in-vehicle network communication, such as CAN bus, LIN bus, etc.
Coaxial cable: used for wireless communication and satellite navigation system.
Shielded cable: used to reduce electromagnetic interference (EMI).
Automotive cable materials
Material selection for automotive cables needs to consider durability, weight, cost and performance. Commonly used conductor materials include:
Copper: good conductivity and ductility, it is the most commonly used conductor material in automotive cables.
Aluminum: sometimes used in large-section cables because it is lighter and less expensive, although its conductivity is not as good as copper.
Insulation and sheath materials usually include:
PVC cable (polyvinyl chloride): economical and widely used, but limited performance at high temperatures.
TPU cable(thermoplastic polyurethane): has better wear resistance and oil resistance.
XLPE cable (cross-linked polyethylene): commonly used in electric vehicle cables, with good electrical properties and heat resistance.
Fluoroplastic cable: used in applications requiring higher temperature and chemical stability.
Specific applications of automotive cables
Automotive cables are widely used in multiple systems in automobiles, including:
Power system: such as battery, generator, starter, lighting system.
Control system: engine management system, brake system, airbag system.
Infotainment system: audio system, navigation system.
Body system: window lift, door lock, air conditioning system.
Safety system: sensor network, camera, radar system.
Features and advantages of automotive cable products
High and low temperature resistance: adapt to the operation of vehicles in different climatic conditions.
Wear resistance: must be able to withstand friction and extrusion when used in small spaces and near moving parts.
Chemical resistance: resist corrosion from chemicals such as oil, coolant, brake fluid.
Electromagnetic compatibility: reduce signal interference and ensure the accuracy of data transmission.
Lightweight: reducing weight helps improve fuel efficiency or the range of electric vehicles.
Safety: low smoke, halogen-free, flame retardant, fireproof.
Principles of selection of automotive cables
Determined according to the insulation degree of the wire, the current passing through and the required mechanical strength. Electrical equipment that works for a long time can choose wires with an actual current carrying capacity of 60%; electrical equipment that works for a short time can choose wires between 60% and 100% of the actual current carrying capacity. The automotive electrical system is a low-voltage power supply with a large working current and a large voltage loss. Excessive voltage loss will affect the normal operation of electrical equipment. Therefore, when selecting the wire cross-section and selection, it is necessary to ensure that the voltage loss does not exceed a certain value: 12V system is not greater than 0.5V, 24V system is not greater than 1.0V, and the actual working current of the wire is not allowed to exceed the allowable current carrying capacity of the wire.
Automotive cable standards
The manufacturing and testing of automotive cables must follow strict standards, such as:
ISO 6722: Automotive wire and cable standards issued by the International Organization for Standardization.
SAE J1125/J1126: Automotive cable performance standards established by the Society of Automotive Engineers (SAE).
DIN 72552: German industrial standard that specifies the characteristics of automotive cables.
Automotive cable testing
- Electrical tests: such as conductor resistance, insulation resistance, capacitance and shielding effect.
- Mechanical tests: such as bending, stretching, torsion and impact tests.
- Environmental tests: such as temperature cycling, damp heat, salt spray and ultraviolet irradiation tests.
- Chemical testing: Evaluate the cable’s resistance to different chemicals.
- Burning testing: Evaluate the cable’s flame retardancy and smoke emissions.
Cooperate with TST CABLES to customize high-quality automotive cables and wiring harnesses
Technology empowers, and safety goes hand in hand. Behind every departure and new journey is the warm protection of TST cables automotive cables. The design and manufacture of automotive cables is a complex engineering process that requires comprehensive consideration of performance, safety and cost to meet the needs of the modern automotive industry. TST cables focuses on the quality of every inch of automotive cables and the careful selection of each layer of insulation, just to build a bridge of trust between you and me. In the ever-changing road conditions, the stable transmission of every signal and every strand of electricity makes driving not only arbitrary movement, but also free enjoyment. Because TST cables automotive equipment cables connect not only the starting point and the end point, but also the warmth of home and inner peace.
If you have any needs for automotive cable and automotive wiring or want to place a sample order, you are welcome to contact us by email or phone at any time.
