The Rectangular Connector is widely used in aerospace, medical instruments, consumer electronics (such as computers, TVs, game consoles, etc.), industrial control equipment, communication equipment, and automotive electronics. With its reliable connection performance, diverse specifications, and relatively convenient plug-in and unplug operations, it has become an indispensable component in various electronic and electrical applications.
High Voltage Connectors are widely used in EV power systems, renewable energy installations, and industrial high-voltage circuits. Renhotec’s series drives the building of efficient, safe, and sustainable electrical ecosystems, meeting current technological demands.
Renhotec EV Cable, crafted with top-notch conductive materials and meticulously engineered insulation, showcases outstanding impedance control and voltage-withstanding properties. Its design combines flexibility and durability to meet a wide array of installation needs. This cable is widely utilized in grid interconnections, large-scale industrial power supply systems, and high-voltage renewable energy projects, enabling smooth and efficient power transmission.
Renhotec, as a professional supplier, offers a comprehensive range of these Signal Transmission Connector products. Whether it is the high-reliability applications of the metal series or the wide adaptability of the plastic series in consumer electronic products, Renhotec can provide customers with high-quality options to meet the diverse requirements of signal transmission connections in different industries and scenarios.
Renhotec, active in electrical components, offers High Voltage DC Contactors in Epoxy Resin Sealing and Ceramic Sealing variants, with a 20A – 1000A current range. The Epoxy Resin Sealing one is cost-effective and protective. The Ceramic Sealing variant excels in thermal stability and insulation. They’re widely used in EV charging, renewable energy grid, and industrial high-voltage DC power distribution for reliable circuit control and current interruption, providing comprehensive solutions for multiple sectors.
The Difference Between Car High Voltage Harness and Household Wire
The two years of renovation, know that you have to buy thicker and thicker wire with more and more appliances at home. The same problem exists for automotive high voltage harness. Household electrical wire is generally a single-stranded copper core wire, thickness in square millimeters (mm²), “4 flat” is the cross-sectional area of 4mm².
Physics tells us that W=I²Rt.
At the same temperature, each wire’s corresponding current carrying capacity is constant. Wire resistance is inversely proportional to the cross-sectional area. The thicker the wire, the lower the resistivity, and the less heat generated by the same current. Once the actual current exceeds the maximum current allowed by the wire, it will cause the wire to overheat and even burn.
This means that the thicker the wire, the greater the number of “flats” that can withstand greater current, the same voltage to withstand greater power. The voltage of home electricity is 220V, according to the rated current and rated power of electrical appliances, to select the most suitable wire.
Reasonable Power of Wires in Domestic Circuits
Cross-sectional Area of Conductors
Suggested Current
Recommended Power
Recommended Appliance
1.5mm²
10A
2200W
Lighting line
2.5mm²
16A
3500W
Common socket
4mm²
25A
4800W
High power appliances
6mm²
36A
6000W
Central air conditioning, incoming bus
10mm²
50A
8500W
Intake bus
How do you calculate the current of more than one appliance in the room, the air conditioner, and the water heater? Household appliances are in parallel. Add up the current of several appliances and compare it with the recommended current of the wire.
The above principle applies to other electricity-using situations, such as new energy vehicles. The two high-voltage wires of the two cars were put together and photographed. According to the above conclusion, the thicker the wire with solid material, the more available power.
There is not just one high voltage wire harness used in new energy vehicles. There are 3mm², 4mm², 16mm², 25mm², 35mm², 50mm² and even 70mm² and many more. For example, in the case of the Rongwei Ei5, the high-voltage wire used for the 85kW motor is different from the high-voltage wire used for the 6.6kW charger at nearly 400V. The “thickness” is the difference in the cross-sectional area of the copper wire, which is also evident.
The specific location distribution on the car can be represented by the following diagram.
So, both are necessary high-voltage wiring harnesses for new energy vehicles, just assembled in different locations according to the power requirements. So if the car is thicker, the wire can not be used? Isn’t this safer?
There is strict management of the weight and space of the parts on the car.
The thicker the wire, the more expensive it is. There is no need for this.
A thicker wiring harness will have a larger turning radius.
1. Household cable for a solid copper core, while the car’s high-voltage cable is most likely composed of multiple thin copper wires.
The reason for this is to increase the conductivity. When the conductor has an alternating current or alternating magnetic field, there will be a “skin effect” the current will be concentrated in the wire’s “skin part “. And the current density on the surface of the conductor is greater than the density of the center. Roughly speaking, it can be understood that the main conductor conducts electricity by the surface.
And the higher the frequency of the alternating current, the more obvious the “skin effect” will be. The high voltage platform of a new energy vehicle is 300-400V, and the frequency can reach kHz level, which is tens of times higher than that of a household appliance, so the high voltage wiring harness must have a reduced “core” area.
And there are other benefits. The main high voltage harness has a cross-sectional area of 50mm², which is 5-10 times thicker than a household appliance. It is much more rigid and difficult to bend. It is difficult to lay out in a car, but it can also pierce into the cockpit after a collision, increasing the safety risk. Considering strength and toughness and safety, multi-core wire is also a better choice.
2. Vehicle High Voltage Wiring Harness with Shielding Layer
Maxwell said that electricity generates magnetism. When a current passes through a wire, a magnetic field is built around it. The shield shields this electromagnetic field within the wire harness. It does not affect other components while reducing electromagnetic radiation. It also shields against external influences and prevents interference from outside magnetic fields.
The basic principle of home and car wiring harness is the same. According to the current and voltage, both need to choose the correct wire, not necessarily the thicker, the better. Moreover, due to the more demanding conditions of use, the standards of automotive high-voltage harnesses are more demanding. The design will also consider more details for safety and durability.
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