High-Voltage EV Cable Assembly Safety Protocols (ISO 6722 Updated)

As electric vehicles (EVs) become more powerful and widespread, the safety of high-voltage cable assemblies has become a top priority. ISO 6722 is the international benchmark for road vehicle wiring¡ªrecent updates have further raised the bar for EV applications. This article explores the latest safety protocols and how to implement them.

What Is ISO 6722?

International standard for single-core cables used in road vehicles.

Specifies performance for thermal, mechanical, and electrical durability.

Key Updates in the Latest Revision

Higher thermal class (up to 150¡ãC continuous)

Improved resistance to abrasion and fluid exposure

Enhanced flammability and fire resistance metrics

Design Considerations for HV EV Assemblies

Voltage Rating: Typically 600V¨C1000V DC

Conductor Types: Fine-stranded copper or aluminum

Insulation: Cross-linked polyethylene (XLPE), silicone rubber, or TPE

Color Coding: Standardized for HV (e.g., orange for live)

Safety Protocols

Shielding: Foil or braided shielding to reduce EMI and increase safety

Insulation Testing: Must exceed minimum dielectric breakdown voltage

Connector Locking Systems: Prevention of accidental disconnection

Thermal Protection: Heat shields or insulation jackets

Assembly Process Controls

Operator training and PPE

Automated cutting and crimping machines for consistency

Inline testing: Continuity, insulation resistance, HiPot

Testing Procedures

Environmental Testing: Humidity, temperature cycles

Mechanical Stress: Vibration and bending endurance

Electrical Safety: HiPot, insulation resistance, and spark testing

Certification Requirements

ISO/TS 16949 compliance for automotive quality systems

Third-party lab validation for new cable designs

Conclusion

With EVs operating at increasingly high voltages, compliance with ISO 6722 is non-negotiable. Adhering to robust safety protocols ensures product reliability and protects both the vehicle and its occupants.