Twisted Thick EV Wire Structure for High-Current Flexibility
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Solution Overview
Problem
Conventional electric wires with large cross-sectional areas for electric vehicles are inflexible and difficult to bend, leading to reduced workability during attachment, necessitating an electric wire with enhanced flexibility and large cross-sectional area for efficient use in electric vehicles.
Innovation Solution
A thick electric wire design featuring a conductor composed of first and second twisted wires with element wires of specific diameters and a secant modulus for the insulating layer, optimized to provide flexibility and handleability, along with a repulsive force and conductor adhesive force within predetermined ranges for improved workability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the cross-sectional area of the electric wire is increased to handle large currents and high voltages, then the current-carrying capacity is improved, but the flexibility and ease of bending deteriorate
Solution Approach 1:
The conductor is divided into multiple element wires (7 to 19 wires) with smaller cross-sectional areas, which are twisted together to form the thick electric wire. This segmentation allows the wire to maintain high current-carrying capacity while improving flexibility, as the multiple smaller wires can bend more easily than a single large wire of equivalent cross-section.
Solution Approach 2:
The electric wire uses a composite structure combining multiple element wires with an insulating layer having specific mechanical properties (secant modulus of 15 MPa to 41 MPa). This composite construction enables the wire to achieve both high current capacity and improved flexibility through the optimized combination of conductor and insulator materials.
2Power
If the cross-sectional area of the electric wire is increased to handle large currents, then the power transmission capability is improved, but the workability during attachment deteriorates
Solution Approach 1:
The conductor is segmented into multiple element wires (7 to 19 wires) that are twisted together. This segmentation maintains high power transmission capability while significantly improving workability during attachment, as the twisted structure is more flexible and easier to route and install compared to a solid wire of equivalent cross-section.
Solution Approach 2:
The insulating layer is designed with specific mechanical parameters (secant modulus of 15 MPa to 41 MPa) that optimize the wire's flexibility and workability. By controlling the secant modulus within this range, the wire achieves improved ease of manipulation and attachment while maintaining the required power transmission capability.
Data Source
AI summary
An electric wire for use in an electric vehicle with a large current of 100 A or more and a high voltage of 30 V or more includes a conductor and an electrically insulating layer covering an outer surface of the conductor, wherein the conductor includes first twisted wires in each of which a plurality of element wires are twisted together, and the first twisted wires are twisted together to form one or more second twisted wires, wherein an element-wire diameter of each of the element wires is 0.18 mm to 0.35 mm, and wherein a secant modulus of the electrically insulating layer is 15 MPa to 41 MPa.