The global sales of electric vehicles (EVs) are estimated to reach approximately 14 million units in 2024. This widespread adoption of electrification extends beyond traditional passenger cars, encompassing commercial fleets of diverse scales transitioning from conventional combustion engines to battery-powered alternatives.
However, for commercial EVs to truly incentivise widespread adoption, they must exhibit efficient performance. Beyond the requisite high-power charging infrastructure, internal components such as e-transport cables within commercial EV designs must facilitate efficient and safe operation.
The high voltages lead to heightened temperatures, and various parts endure prolonged exposure to extreme environmental conditions such as dust, water, and dirt. This means specialist cables are required in order to connect these charging devices.
Key Components for High-Power EVs
Cables
EV charging cables act as the vital conduits that channel power to various components, ranging from the battery pack to the electric climate compressor. For high-power EVs, cables must endure continuous and extreme voltage levels without succumbing to electrical stress.
Consequently, high-voltage cables are fortified with additional layers of insulation to effectively control the electric field surrounding the conductor, albeit at the expense of increased weight and bulkiness. Therefore, it's important for high-power EV designs to incorporate cables with sufficient thermal insulation to maintain design flexibility without unnecessary weight and bulk.
Connectors
Connectors play a crucial role in delivering power to individual devices, each with distinct electrical requirements. In high-power EVs, connectors must exhibit ruggedness and high performance to withstand the rigours of high-voltage environments.
Furthermore, external components like sensors demand specialised solutions such as hermetic and environmental sealing to ensure safety and uninterrupted operation. When selecting connector solutions for high-power EV designs, it's paramount to prioritise components offering effective vibration shielding and protection against external elements for sustained functionality and safety over the long term.
E-Mobility Cables at Cableworld
EV-Ultra®
Tailored for electric vehicle charge points, this cable combines power conductors and a screened 2-core data cable in a double-sheathed design for enhanced protection. Versatile for various installations requiring power and a 2-core data/signal cable, it is suitable for air installation, surface clipping, cable tray/ladder work, and concrete embedding. Additionally, it can be laid directly in the ground with appropriate mechanical protection.
EV-Ultra® + Cat5e
Designed specifically for electric vehicle charge point installations, EV-Ultra® seamlessly integrates power conductors and a 2-core screened data cable within a double-sheathed design, offering enhanced protection for installers requiring both power and data.
Available in 3-core and 5-core variations, these cables meet the specific requirements of single and three-phase EV charge points. Suitable for diverse installations, including air, surface clipping, cable tray/ladder work, and embedding in concrete.
In the absence of a recognised British Standard for these cables, installers face challenges when handling products not manufactured to national or international standards. According to BS7671, the responsibility for ensuring safety falls on the installer and/or specifier when equipment is not covered by a British or Harmonized Standard.
Full third-party accreditation from BASEC provides a robust solution, ensuring that EV-Ultra® meets necessary safety and performance requirements. This accreditation empowers installers to demonstrate the cable's suitability without assuming personal responsibility.
Utilising specially developed CarbonTek technology, EV-Ultra® introduces a compound with high abrasion resistance, high impact resistance, thermal stability, UV stability, and enhanced flexibility. CarbonTek reduces installation effort, facilitating a quicker, neater, and easier process for installers.
Regulations define Voltage Band I as levels too low to cause serious electric shocks, covering extra-low voltage (ELV) applications. Voltage Band II includes all voltages not in Band I, such as 230V supplies. Proximity of electrical services mandates insulation criteria for Band I and Band II circuits within the same wiring system.
EV-Ultra® eliminates the need for segregation of power and data, comprising power conductors and data cables rated to the same nominal voltage.
Addressing electrical interference concerns, EV-Ultra® incorporates screened, twisted pair data cables and a lay length designed to reduce interference. Third-party data testing under BASEC approval confirms the successful design solution, ensuring excellent data transmission without interference.
EV-Ultra® - Power & Data Combined (Cat5) at Cableworld
Unlock the future of electric vehicle charging with EV-Ultra® Power and Data Combined (Cat5) from Cableworld.
NYY PVC NON-ARMOURED LV POWER CABLE
Non-armoured power cables for fixed installation indoors or outdoors, in the ground, in water or in concrete.
H07Z-R (6491B)
Commonly used in conduit or as an earth cable. The low smoke zero halogen construction makes this cable suited to installations where, when subjected to fire, the emission of smoke and toxic gas may present a threat.
H07V-R (6491X)
Commonly used in conduit, fixed installation for power and/or lighting circuits or as an earth cable.
E-Transport Cables at Cableworld
Explore our wide range of e-transport cables from Cableworld or get in touch with our exports to find out more information about the cables you require for your projects.
