Alternative fuel vehicles, especially hybrid-electrical vehicles (HEV) are rapidly gaining market shares around the world due to increasing gasoline prices, the rising awareness of global warming and federal tax incentives. Whereas HEV’s combine an internal combustion engine with an electric motor that supports the gasoline engine during acceleration and low speed condition when the combustion engine is not efficient, fuel cell vehicles are solely propelled by an electric motor.
Both concepts have in common that they use high voltage batteries with voltages of 600 volts and higher to power the electric power train.
This paper aims to address the requirements of various OEMs and harness makers for high voltage cables used on board of HEV vehicles to connect high voltage battery, inverter, AC compressor, 3-phase generator and 3-phase motor.
Furthermore the challenges automotive suppliers face, including mechanical and electrical requirements, in comparison to existing designs using standard low voltage cables, are presented. Design tools and material and cable options to overcome the challenges, while meeting the stringent requirements of the automotive industry, are also highlighted in this paper.