What makes high voltage different
In a vehicle, high voltage means voltages above 60 volts DC or 30 volts AC. In electric and hybrid vehicles the voltages are typically several hundred volts. That brings dielectric strength, touch protection and electromagnetic compatibility to the fore; the high currents call for large cross sections and carefully dimensioned contacts.
Typical characteristics
- Cables with reinforced insulation, usually marked orange in the vehicle
- Shielded cables and connectors with the shield contacted throughout
- Connectors with touch protection and often a safety interlock loop (HVIL)
- Large cross sections and contact systems rated for the current
- Safe physical separation of high and low voltage cables
Testing high voltage cable sets
Alongside continuity and short circuits, high voltage also calls for a test of the dielectric strength, with test voltages well above the operating voltage. Depending on the specification, insulation resistance, shield continuity and a test of the safety interlock loop are added. The customer specification defines the test voltage and the scope.
The article Testing wiring harnesses gives an overview of all types of test.
High voltage at Powertune
We supply high voltage cable sets with an insulation concept, shielding and safe separation of high and low voltage. For this we process cross sections up to 70 mm², and up to 95 mm² where required. We define the scope of testing, including the high voltage test, for each project. More on this under Wiring harnesses for the automotive industry.
