High voltage cables are crucial components in electrical systems, ensuring efficient energy transfer and reliable operation. Whether you’re designing, installing, or maintaining electrical equipment, understanding high voltage cable design is key to optimising performance and avoiding common mistakes.
Why High Voltage Cable Design is Important
One common mistake that many design engineers make is not considering the cables and interconnections until the final stages of the project when other parts of the equipment are already developed. However, cable design plays a critical role in the system’s overall performance.
High voltage (HV) connectors, depending on the voltage level, are often large and require adequate insulation space within the equipment. The design of these cables can significantly impact the size, functionality, and safety of the system. Thus, it’s important to integrate cable considerations early in the design process.
Need Expert Help?
At Genvolt, we specialise in the supply and design of high voltage cables and connectors. If you need assistance with your high voltage cable requirements, feel free to contact us for expert guidance.
Important Considerations for High Voltage Cable Design
When designing high voltage cables, it’s essential to consider the following factors to ensure optimal performance and safety:
1. Voltage Levels and Frequency
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For applications with pulsed DC and fast rise times, or AC voltages, it’s crucial to choose a cable with a suitable insulation or dielectric layer to maintain the voltage shape.
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Low DC voltage systems may not require the same considerations, but the cable design will still affect diameter, flexibility, and cost.
2. Current Level
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The cable’s continuous or pulsed current capacity is influenced by the conductor’s diameter, material (usually copper), and the cable’s construction.
3. Shielded vs. Non-Shielded Cables
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Shielded cables offer additional safety and protection. They also provide a current return path between connected equipment. Ensure that the braid has the appropriate current rating.
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Non-shielded cables are typically used for internal high voltage applications.
4. Temperature Considerations
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Ambient external temperatures and internally generated heat can influence the selection of dielectric materials. Materials such as FEP and Silicone are rated up to 190°C.
5. Flexibility
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The conductor construction, dielectric material, shield, and jacket all impact the overall flexibility and diameter of the cable.
6. Cable Diameter
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The conductor size, dielectric material type, shield, and jacket all affect the overall diameter of the cable for a given voltage.
7. Inductance and Capacitance
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These characteristics are governed by the cable’s diameter and the dielectric material used.
8. Resistance and Impedance
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Resistance is determined by the conductor size, while impedance is influenced by the dielectric diameter and material type.
9. Multiple Conductors
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Adequate voltage separation is necessary between conductors, shields, and ground potential. Choose dielectric materials that offer the right balance of flexibility and diameter.
10. Jacket Material
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The cable jacket material affects flexibility, toughness, temperature rating, and even the cable’s colour. Select a jacket material that fits your application requirements.
Genvolt Custom High Voltage Cable Designs
At Genvolt, we specialise in custom high voltage cable designs. If you have specific technical requirements related to voltage, diameter, temperature, colour, or any other unique specifications, we can design a custom cable tailored to your application.
Conclusion
High voltage cables are essential to the efficient operation of electrical systems, enabling reliable energy transfer and performance. As a design engineer, understanding the intricacies of high voltage cable design will help you optimise your system and prevent costly issues.
We hope this guide provides valuable insights into high voltage cable considerations. If you have any questions or need assistance with your cable design, don’t hesitate to contact us. We’re here to help!