BLOG

Differences between High-Voltage Cables for Electric Vehicles and Charging Cables for Charging Stations

Release Date：

2019-10-18

The era of internal-combustion-engine vehicles is inevitably coming to an end. Under the combined pressures of policy, energy supply, and environmental concerns, new-energy vehicles have become the dominant trend. “New-energy cables” is the shorthand term for the wiring and cable systems used in new-energy vehicles, which are broadly categorized into two main types: on-board (in-vehicle) cables and off-board (charging-station) cables. Over the next few years, both new-energy vehicles and charging stations are expected to maintain strong growth, and as the backbone for power transmission, new-energy cables will likewise experience explosive growth in tandem with the expansion of the new-energy vehicle market. New-energy vehicle cables do differ to some extent from conventional automotive cables:

1. Internationally, the color of high-voltage wiring in electric vehicles is standardized as orange; no specific color requirements are stipulated for charging cables.

2. High-voltage cables for electric vehicles must meet automotive wear-resistance requirements; charging cables must meet the crush-resistant requirements for mobile cables.

3. International standards for high-voltage wiring in electric vehicles are developed by the ISO, while international standards for charging cables are developed by the IEC.

4. High-voltage cables for electric vehicles must be resistant to all liquids encountered inside the vehicle; charging cables must be resistant to all liquids in the vehicle’s external operating environment.

5. Necessary protective measures must be implemented around high-voltage wiring in electric vehicles; charging cables, lacking such protection, are subjected to various mechanical impacts and prolonged exposure to ultraviolet radiation.

6. High-voltage cables in electric vehicles are installed in a fixed manner, with only a few localized points requiring a very small static bending radius; charging cables, by contrast, are installed in a mobile manner and therefore require a small dynamic bending radius.

7. High-voltage cables for electric vehicles are subject to space constraints and have stringent size requirements, with a preference for the smallest possible dimensions; in contrast, charging cables have no size limitations and can be made thicker and larger.

8. For ease of installation, high-voltage wiring in electric vehicles typically uses single-core cables; charging cables, on the other hand, are usually multi-core integrated cables that incorporate a high-voltage main conductor, a ground conductor, low-voltage signal lines, and even dual-function communication lines (such as CAN).

9. The higher the heat resistance of high-voltage wiring in electric vehicles, the better—higher heat resistance translates to greater current-carrying capacity. As a result, the standard starting point is 125°C, with some materials reaching as high as 180°C (silicone rubber) or even 200°C (fluororubber). However, charging cables must not overheat; their maximum operating temperature should never exceed 70°C, as excessive heat could cause burns.

10. To ensure that in-vehicle communication and control functions are not affected, high-voltage cables for electric vehicles have stringent EMI requirements and must comply with automotive EMC standards. During charging, when the vehicle is stationary, the charging cable is not required to meet automotive EMC standards; it only needs to comply with the relevant EMC standards for the specific installation environment, such as those applicable at gas stations or residential communities.

Guided by its corporate mission of “Green Innovation for the Benefit of Humanity,” Aomeige has, since 2009, committed substantial resources to the independent R&D of conductive products for new-energy electric vehicles. By 2011, the company had achieved significant breakthroughs in product development, market expansion, and industry certification. In terms of certification, Aomeige became one of the first domestic enterprises to obtain UL certification; following UL, it subsequently secured certifications from TÜV Rheinland, China’s CQC, and China’s DEKRA. On the market-expansion front, Aomeige’s products and technologies are now serving major vehicle manufacturers and well-known connector companies.

Return to list →

More information

2026-04-10

Meaning of Letters in Wires and Cables