Safety first!

With the high-voltage cable assemblies from CiS you are on the safe side!

high voltage cable assembly

High voltage cable assembly

High voltage cable assembly

In times of electric mobility and hybrid drives, high-voltage cables are becoming increasingly important. They are an important component of electric and hybrid vehicles and enable invisible power transmission between the individual components. Let us support the vision of a green vehicle electrical system together and promote more environmentally friendly mobility with our high-voltage cables.

With over 45 years of experience, we are your expert when it comes to processing high-voltage cable assemblies. Our expert consultants accompany you from the initial idea to series production. In cooperation with our customers, we develop and manufacture individual solutions. When it comes to cable assembly, we can process components from all manufacturers currently on the market.

Are you facing a new challenge and looking for a stable partner at your side? – Then CiS is the right place for you!

What does high-voltage mean?

But what exactly are high-voltage cables? The term high-voltage system comes from automotive engineering and describes a system that is operated with alternating voltages above 30V to 1kV or with direct voltages above 60V to 1.5kV.

A „high-voltage battery“ (400V to 800V) or „high-voltage storage“ is an electrical energy source for mobile and stationary applications. When used in vehicles, it is also referred to as a traction battery.

Function of high-voltage cables: the voltage increases

High-voltage cables are used to transmit high electrical voltages that are required in electric vehicles and hybrid vehicles to supply the electrical drive components. They transport the current from the battery to the motor, the generator and the other electrical consumers in the vehicle. Despite their high performance, high-voltage cables are particularly space- and weight-saving due to their innovative design, which enables electric vehicles to have a longer range and supports CO2 regulation.

It should be noted that high-voltage connectors are used in this area. As connectors establish the electrical connection between electronic high-voltage components, maximum safety is required here.

Through our careful and conscientious electrical testing, we guarantee you above all reliability and safety at the highest level of quality. Would you like to gain a short insight into the electrical testing in our production halls? Then we invite you to take our virtual tour.


How is a high-voltage cable constructed?

High-voltage cables consist of different layers that are crucial for their function. The outer layer is an insulation layer that protects the cable from moisture, dust and other environmental influences.

Underneath is a shield that reduces electromagnetic interference and stabilises the current flow. In the middle of the cable is the actual conductor, which is made of copper or aluminium and transports the current. Depending on the requirements, several conductors can be installed in one cable.


High-voltage cables for electric cars and the like: What requirements must they fulfil?

High-voltage cables must meet various requirements to be suitable for use in electric cars and hybrid vehicles. These include:

  • High dielectric strength: High-voltage cables must be able to withstand voltages of several hundred volts without failing or breaking through.
  • Low losses: High-voltage cables must transmit the current with as little loss as possible to ensure energy efficiency.
  • Good insulation: The insulation layer must insulate the current and at the same time protect it from environmental influences.
  • Robust construction: High-voltage cables must be shock and vibration resistant and must not wear through or wear out.
  • Temperature resistance: High-voltage cables must remain stable and functional even at high and low temperatures.

With know-how and comprehensive expertise, CiS develops and produces individual solutions for high-voltage connections – naturally in accordance with the highest quality standards, such as the norms and standards of the VDA. Get in touch with us now.

In addition to high-voltage cables, we supply you with other products of the highest quality. We are also there for you when it comes to cable assemblyelectromechanical componentssystem technologyinput systems and development services.

Where are high-voltage cables used?

High-voltage cables are mainly used in electric cars and hybrid vehicles. There, they transport the current between the electrical components. In addition to their function in electric and hybrid vehicles, high-voltage cables are also used in other applications, such as power engineering and industry. Here, for example, they are used to transport direct current or alternating current. High-voltage cables are also used in fuel cells, high-voltage batteries and electrified wiring systems, where they ensure efficient energy transmission.

High-voltage cables are used wherever vehicles need to be electrically driven, such as:

  • Hybrid and electric vehicles
  • Agricultural vehicles
  • Fuel cell vehicles
  • Electric scooters and electric motorcycles
  • Industrial trucks
  • Other commercial vehicles

What is the difference between a high-voltage cable and a low-voltage cable?

he main difference between a high-voltage cable and a low-voltage cable is the voltage that is transported. High-voltage cables carry voltages in the range of several hundred to 1,000 volts, while low-voltage cables only carry voltages of up to 50 volts. As a result, there are specified safety regulations for high-voltage cables which must be observed.

Are you looking for a competent partner with experience in the high-voltage sector? – Then please contact our technical advisors. We look forward to your enquiry!