Product Overview
The 120A 600V High-Current New Energy Cable from SUYI Electronics is a high-performance solution for new energy vehicle (NEV) high-voltage interconnection systems. It specializes in transferring high-power energy from the vehicle’s battery pack to critical components like motor controllers, DC-DC converters, and on-board chargers. Unlike traditional high-voltage cables, it is engineered to withstand NEVs’ complex operating conditions (vibration, extreme temperatures, chemical exposure), ensuring safe, low-loss energy transmission. With a rated current of 120A (and optional 50A) and voltage of 600V, it is a core component of NEV wiring harnesses and new energy connectors.
Key Features
120A High Current Rating: Carries up to 120A of continuous current, meeting high-power demands of NEV propulsion systems.
600V High Voltage Tolerance: Withstands 600V AC/DC, complying with SAE J1673 and IEC 60287 NEV safety standards.
Extreme Environment Resistance: Operates in –40℃~+125℃, resists vibration (ISO 16750-3) and automotive fluids (oil, coolant).
Low Power Loss: Uses oxygen-free copper conductors (low resistance) to minimize energy waste during transmission.
Flame-Retardant Insulation: XLPE (Cross-Linked Polyethylene) insulation meets UL94 V-0, reducing fire risks in high-power operation.
NEV Connector Compatibility: Designed to match standard new energy connectors, simplifying integration into existing harnesses.
50A Optional Variant: Available for low-power components (e.g., auxiliary power systems), offering application versatility.
Flexible Routing: Balanced flexibility allows installation in tight NEV chassis spaces, cutting assembly time.
Specifications & Technical Details
Parameter | Specification |
Model | 120A 600V High-Current New Energy Cable |
Brand | SUYI |
Rated Current | 120A (continuous); 50A (optional) |
Rated Voltage | 600V AC/DC |
Conductor Material | Oxygen-free copper (99.99% purity, high conductivity) |
Insulation Material | Flame-retardant XLPE |
Operating Temperature | –40℃ ~ +125℃ |
Flame Rating | UL94 V-0 |
Vibration Resistance | Complies with ISO 16750-3 (automotive vibration standards) |
Compatibility | NEV battery packs, motor controllers, DC-DC converters, on-board chargers |
Standard Length | 1m–5m (customizable up to 100m) |
Product Application Scenarios
Transfers energy between the battery pack and high-voltage distribution unit (HVDU), ensuring stable power supply to the propulsion system.
Links the HVDU to the motor controller, delivering high current to drive the electric motor with minimal power loss.
Supplies high-voltage power to the DC-DC converter, which steps down voltage for low-voltage systems (lights, infotainment).
Connects the OBC to the battery pack, enabling efficient charging by transmitting high current from the charger to the battery.
Extends to stationary ESS (e.g., solar storage), transferring high current between batteries and inverters.
Customization Service Process
Demand Assessment
Engineers confirm requirements: current rating (50A/120A/custom), length, insulation grade, and connector compatibility.
Technical Scheme Design
Optimizes conductor cross-sectional area, insulation thickness, and flame-retardant properties for target applications.
Prototype Testing
Prototypes undergo current-carrying, voltage-withstand, and vibration tests; test reports are provided for customer approval.
Mass Production
Precision extrusion equipment ensures consistency, with real-time monitoring of conductor resistance and insulation integrity.
Delivery & Installation Guidance
JIT (Just-In-Time) delivery is offered for NEV manufacturers, with on-site technical support for harness assembly.
Quality Assurance & After-Sales Support
Quality Control Measures
Current carrying test: 120A stable operation for 1000 hours (no overheating).
High-voltage test: 900V (1.5x rated) for 1 minute (no breakdown).
Environmental test: Temperature cycling, salt spray, and vibration validation.
Flame test: UL94 V-0 compliance to prevent fire spread.
After-Sales Service
Warranty: 24-month coverage for material/workmanship defects.
On-site support: Technicians dispatched for bulk-order troubleshooting.
Replacement: Free replacements for qualified issues, with fast turnaround.
Compliance consultation: Guidance on IEC/SAE standards for global exports.
FAQ
Can the current rating exceed 120A?
Yes, we customize ratings (150A, 200A) by adjusting conductor cross-section. Our team optimizes design for high-power needs.
How is this cable different from traditional ICE vehicle cables?
Traditional cables handle ≤50A (e.g., starter motors). Our High-Current New Energy Cable supports 120A/600V with better heat/vibration resistance—critical for NEVs.
Is the insulation resistant to automotive fluids?
Yes, XLPE insulation resists oil, coolant, and brake fluid, preventing degradation in under-vehicle environments.
What is the minimum bending radius?
5x the cable diameter (e.g., 25mm for 5mm diameter), ensuring flexibility without conductor damage.
Does it comply with international NEV standards?
Yes, it meets IEC 60287 (conductive cables) and SAE J1673 (automotive high-voltage), suitable for global markets.
