New Energy Power truck parts Multi in one to high voltage distribution box high voltage cable assembly 2105030-KT2A1

Built for reliable high-power transmission between core NEV components, this cable assembly delivers exceptional electrical performance. The conductor uses 99.9% pure oxygen-free copper (OFC) with a 50mm² cross-section, featuring a 7×19 strand structure that minimizes DC resistance (≤0.00036Ω/m). This low resistance reduces voltage drop to ≤1.5V at 250A load, cutting energy loss by 25% compared to standard copper-clad aluminum cables. The cable’s rated current capacity (250A continuous, 500A peak for 10s) supports the high-power demands of 300kW+ multi-in-one controllers, ensuring stable power delivery during acceleration or heavy-haul operations. The twisted-pair conductor design enhances electromagnetic compatibility (EMC), reducing interference with low-voltage signals and complying with CISPR 25 Class 3 standards

Engineered as a critical safety component in NEV high-voltage systems, the cable assembly integrates multi-layer protections. The conductor is insulated with cross-linked polyethylene (XLPE) material, providing 10kV/mm dielectric strength and resisting 150℃ continuous temperature—preventing insulation breakdown and electric arcing. A copper braid shielding layer (coverage ≥95%) isolates external electromagnetic interference (EMI) and serves as a ground path, while the flame-retardant PVC outer sheath (UL94 V-0 rating) inhibits fire spread. The connectors feature double O-ring seals (Viton material) for IP67 waterproofing and integrated voltage detection pins that trigger the vehicle’s high-voltage interlock (HVIL) system if disconnected—eliminating electric shock risks for maintenance personnel

Designed for the rigorous demands of commercial NEVs, the cable assembly exhibits exceptional durability across diverse climates and road conditions. The XLPE insulation maintains flexibility at -40℃ (northeast China winters) and resists aging at 85℃ (desert regions), passing 3000-hour thermal cycle testing (-30℃ to 100℃) without cracking. The outer sheath resists chemical corrosion from road salt, battery electrolyte, and cleaning agents, with no volume change after 72-hour immersion in alkaline solution. The assembly passes 500,000 vibration cycles (5-2000Hz, ISO 16750-3) with no connector loosening and 1000-hour salt spray testing (ASTM B117) with no shielding corrosion. Its abrasion-resistant sheath (wear resistance ≥100,000 cycles) withstands friction from chassis components, ensuring a service life of ≥8 years/400,000km

Optimized for efficient NEV fleet maintenance, the cable assembly features a pre-assembled plug-and-play design that reduces installation time by 60%. It comes fully terminated with connectors, pre-tightened to OE torque specifications (15-20N·m), and equipped with pre-installed mounting clips that match the chassis’s original holes—requiring only a cable tie gun for secure routing. The connectors’ keyed design prevents reverse installation, while color-coding (red for positive, black for negative) simplifies identification. A service loop (150mm excess length) at the midpoint allows for easy disassembly during component maintenance, and the cable’s printed length markers facilitate precise routing. A single technician can complete the entire installation in 25 minutes or less, minimizing truck downtime and reducing labor costs