New Energy Power parts Controller high-voltage cable assembly 2105050-KT1D0

The cable uses tinned copper stranded conductors (strand count: 19-61, single wire diameter: 0.2-0.5mm) for low resistance (≤0.0012Ω/m at 20°C) and excellent current-carrying capacity. It supports a maximum continuous current of 200A and peak current of 400A (for 10ms), meeting the transient current demands of NEV controller start-up and acceleration. The insulation layer is made of cross-linked polyethylene (XLPE) with a thickness of 1.5-2.5mm, providing high dielectric strength (≥20kV/mm) and resistance to partial discharge—preventing electrical breakdown in high-voltage environments. Voltage drop is controlled below 0.5V per meter, ensuring stable controller operation

Tailored for NEV high-voltage safety, the assembly integrates multiple protective features: high-voltage insulation (insulation resistance ≥1000MΩ at 1000V DC) to prevent electric shock, and a tinned copper braided shielding layer (coverage rate ≥95%) that reduces electromagnetic interference (EMI) between the cable and nearby low-voltage signals (e.g., BMS data lines). The shielding layer is grounded via the connector, further enhancing EMI suppression. Additionally, the cable jacket is made of flame-retardant TPU material (UL94 V-0 rating) that self-extinguishes within 10 seconds, inhibiting fire spread in case of short circuits—critical for NEV safety compliance (e.g., GB/T 18487.1)

The cable jacket exhibits excellent environmental adaptability: it withstands extreme temperatures (-40°C to 125°C) without hardening or cracking, and resists oil, fuel, and road salt corrosion (passes 1000-hour immersion tests in engine oil). The high-voltage connectors use high-impact PBT plastic housings (surface hardness: HB) and nickel-plated copper contacts (plating thickness: ≥5μm) for wear resistance—supporting 50+ mating cycles without contact degradation. The cable’s bend radius is ≥5× cable outer diameter, ensuring flexibility for chassis routing while avoiding insulation damage during installation or vehicle vibration (frequency: 10-500Hz)

The assembly adopts a plug-and-play design with pre-crimped connectors (crimping force: 8-15kN) that require no on-site crimping, reducing installation time by 50%. The connectors feature a mechanical locking mechanism (twist-lock or push-to-lock) that prevents accidental disconnection, and the cable is pre-marked with position labels (e.g., "Controller-PDU," "Positive/Negative") for error-free wiring. Mounting clips (included) with rubber gaskets secure the cable to the NEV chassis, avoiding friction with metal components. The assembly complies with international high-voltage standards (e.g., IEC 60502-2) and NEV safety regulations, ensuring compliance with vehicle certification requirements