Preface
This article has been compiled with the aim of familiarizing readers with what automotive cables are, and respected users will get to know the products of Kerman Zarcable in the field of automotive cables after studying this category of cables. In short, automotive cables refer to cables that are used in motor vehicles and its operation in cars causes the transfer of various currents between the components of the cars.
Type Of Cables
All types of cables are divided into four categories based on the intensity of voltage: low pressure, medium pressure, high pressure and extra high pressure. These cables are displayed with the abbreviations LV, MV, HV and EHV respectively. The voltage level of low voltage cables is less than 1 kV, medium voltage cables are 33 to 1000 kV, high voltage cables are 63 kV to 230 kV, and extra high voltage cables are 400 kV and more.
Low Voltage Cable
Low voltage cables have various applications in commercial, residential and industrial environments. This category of cables is used to transmit power less than 1k lV and also to transmit signals such as information, audio or video. Low voltage cables are usually made of copper or aluminum and insulated with various materials including PVC, Rubber or Fiberglass.
Automotive Cables, What Are They?
Automotive cables play an effective role in vehicles. In cars, these cables and wires are used to transfer electric power between power generation or storage sources such as alternators and batteries, as well as all sensors and actuators and other car comfort systems such as audio and video devices, lights and other components. High temperature resistance and tolerance, wires not being dry and their flexibility for better placement are among the features that automotive cables must have. Also, the conductor part of automotive cables must have high conductivity, that’s why copper metal is more useful for this category of products. The speed of current transmission in automotive cables is one of the most important factors of this type of cables.
Importance Of Automotive Cables
The use of automobile cables can be better understood by removing them. Failure to transfer currents from the battery to other places, failure of the audio system and turning off the lights of the car, all of which will be disturbed in the absence of cables.
With the introduction of electric cars, the demand for wires and cables in the automotive industry has increased and has created a challenge for its design. Electric motors of hybrid cars create the need for more space in the design of cars, which can affect the increase in the weight of vehicles, which will result in the need to consume more fuel. From another point of view, more space for more cables should be considered in these designs.
Primary Cables or GPT
These wires are the most common wires in the wiring system of any vehicle. Primary wire (GPT) has a single core with multi-filament that can fit into tighter spaces. They are mainly used for interior wiring of cars. GPT wires should not be left outdoors for long periods of time. The primary internal wires of cars can withstand temperatures up to 80 degrees Celsius. They can also withstand chemicals, acids and oils without complications.
Automotive Cable Insulation
The insulation material of the cable is affected by factors such as resistance to heat, cold and freezing, humidity, exposure to contact with liquids and protection against impact and wear. The insulating material of low voltage cables is usually made of PVC, rubber and fiberglass, which are explained below.
– Polyvinyl chloride or PVC:It is a relatively cheap insulation that withstands temperatures up to +105 degrees Celsius and is resistant to flame, moisture and abrasion. It can also withstand gasoline, ozone, acids, solvents and other industrial chemicals. PVC materials are odorless, tasteless and non-toxic. One of the downsides of PVC insulation is its high capacitance drop, which means there is some performance degradation compared to other insulation materials that can be used in an electrical system. Also, this insulation shows little flexibility when used in tensile applications.
– Rubber: all natural rubber compounds that have different types and are used in a wide range of different applications. Rubber insulation has poor resistance to oil and ozone, but has good flexibility and electrical properties at low temperatures, and is also resistant to water, alcohol, and abrasion.
– Fiberglass: Fiberglass is the most widely used glass insulation and can be used continuously up to an operating temperature of +482 degrees Celsius. Although fiberglass is resistant to moisture and chemicals, it has little resistance to abrasion.
According to the used position of automotive cables, the insulation used can be made of PVC type one and polyethylene.
The Difference Between Residential And Automotive Cables
Automotive wires are often used in harsh vehicle environments. For example, automotive cables used in the car engine are easily damaged by contact with battery acid if they are ordinary wires. Normal wires used in residential houses have less resistance, according to the way and environment they are used. And vice versa, car wires can withstand high temperatures and chemical corrosion. Also, car wiring has a stronger and more reliable protective layer, while also being more flexible than ordinary wires.
The wires used in residential buildings are cheaper compared to automotive cables, but we must not forget that differences such as the high resistance of automotive wires make ordinary wires less durable compared to automotive wires. As a result, using them in cars will reduce the life of the cable and make them vulnerable in the short term. Also, if the insulation of the wires is not suitable, the possibility of its being flammable in contact with liquids increases. For this reason, replacing car cables with other cables with similar performance can bring many risks.
Common Causes Of Failure In Cables
Damage to cables can occur for various reasons such as burns and have many consequences such as damaging other parts of a car, some of the most frequent and common ones are listed below.
On uneven roads, due to the continuous vibration of the car and the severe tension of the handles connected to the engine or chassis, it has a strong effect on the wiring of the car, which challenges the flexibility of the wires in the long run. Also, placing the car in environments that are exposed to extreme temperatures and humidity also has a great impact on car cables.
In some climates, car wiring harnesses are constantly exposed to extreme weather conditions, and rainwater hits the engine and chassis through the tires to the wires, which corrodes the insulation, making the copper wires more vulnerable over time and eventually leading to wire breakage.
Another problem that damages car cables is overheating. For example, we can mention abnormal currents passing through the wires, the low capacity of the wiring compared to the amount of current required by the car, and the overheating of parts due to technical defects that expose the wiring adjacent to these parts to damage.
Variety Of Cable Color Codes
Using different colors is very important when repairing or replacing wires. Creating a distinction in the color of the cables will make it easier to recognize them when they are crowded or in an inappropriate position and will make them easier to access.
Conclusion
Kerman Zarcable Company is one of the leading companies in the field of producing and supplying low voltage copper and aluminum cables in the country with the production of various products in various fields including electricity, precision instruments and telecommunications as well as automotive cables. Since the beginning of the journey in 2003, this company has succeeded in obtaining various international certificates, which is a confirmation of the credibility of this company and the trust of its customers. At the end of this article, some examples of car cables of Kerman Zarcable company are displayed. To visit all products and more informaton, visit product page.
In the end, it can be said that, the role of cables in cars may seem insignificant, but the importance of their performance can be compared to the importance of the veins of the body, which cause the transfer of various currents between car components. The type of insulation and the level of resistance and conductivity of automotive cables make the difference between these types of cables and ordinary cables.
