Automotive High Voltage Cable Standards
Automotive high voltage cable standards have improved significantly with the development of electric vehicles.
Currently there are the following common standards:
- ISO 6722, ISO 19642 of the International Organization for Standardization.
- LV216-2 of the German Association of the Automotive Industry.
- UL758 issued by UL Laboratories, USA.
ISO 19642
This standard regulates high-voltage vehicle cables, conductors, jackets, shields, and outer diameters. It applies to the design, production and testing of cables for electric vehicles more generally as a reference.
This standard defines clear tolerances for the outer diameter of high voltage cables for automotive applications, bringing consistency to cable dimensions. This reduces the number of customized cables and connectors, ultimately reducing costs.
“There are often cases in the industry where Family A’s connectors are applicable to a range of cable ODs and Family B’s connectors are a range. However, the connectors of family A and family B have to be connected to a cable, in order to solve this problem it is often necessary to use temporary gluing this measure. This measure, basically after a certain period of time will be wrong.”
ISO 6722
This standard is a specification for single-core wire size conductors inside vehicles and test methods. The conductor section of ISO 19642 is basically referenced to this standard.
LV216-2
As a standard issued by the German Association of the Automotive Industry, manufacturers in the European region prefer to follow their specifications. This standard has very strict requirements for the safety and stability of cables. There are more stringent insulation tests, voltage tests and mechanical tests.
Common cable types: FHL2G, FHLR2GCB2G
UL758
This standard is more applicable to the US wire gauge countries. It defines the conductor specifications for cables used in vehicles, covering low voltage, medium voltage and high voltage. The is more of a specification for the construction of the conductors on the vehicle as well as the size.
Recommendations by Region
If you are in Europe, I would recommend that you refer to the LV216-2 standard for your cables when manufacturing or modifying your vehicle.
If you are in other region, I would recommend that you refer to ISO 6722 and ISO 19642 for your cables.
However, if your cables are US gauge, you may need some advice from your engineers to select the right cable for your OD.
Supplier
Our preferred supplier is LOENI, who have proven experience in the design and manufacture of high voltage automotive wiring harnesses.
If you only need to purchase HV EV cables, please feel free to consult us. We are experienced in controlling the OD of high voltage automotive cables.
