What is a high-voltage cable from a professional perspective?

1. Definition of high-voltage cable

1. Based on insulation material and application scenario, they can be divided into general-purpose cross-linked polyethylene cables, flame-retardant/fire-resistant cables, mining rubber-sheathed flexible cables, and high-voltage test cables, etc.
2. Based on transmission type, they can be divided into high-voltage AC cables and high-voltage DC cables.
3. Based on deployment location, they can be divided into overhead cables, underground cables, and submarine cables.

2. The structure of high-voltage cables

High-voltage cables have a complex structure, mainly consisting of the following layers from the inside out: conductor layer, insulation layer, shielding layer (including a metal sheath), and outer sheath.

1. The conductor layer is the core of the cable, responsible for transmitting current, and is typically made of copper or aluminum.
2. The insulation layer wraps around the conductor, preventing current loss to the surrounding environment. Insulation materials are usually polyethylene (PE), cross-linked polyethylene (XLPE), or rubber. As the mainstream insulation material, the production and quality control of cross-linked polyethylene (XLPE) are crucial. During insulation extrusion, strict control of the process temperature (e.g., the insulation material processing temperature range is between 115-120℃), prevention of pre-crosslinking, and the use of online thermal stress relaxation systems are necessary to eliminate thermal stress. Simultaneously, precise control of the extrusion die, vulcanization temperature (insulation surface temperature strictly controlled between 250-280℃), and the use of catenary production line eccentricity control technology ensure the uniformity of the insulation layer.
3. The metal sheath layer mainly provides mechanical protection and electromagnetic shielding for the cable. Depending on specific design and application requirements, the metal shielding layer can take different forms, such as corrugated aluminum sheath or copper wire shielding. In some high-voltage cables, multiple layers of insulation may be present to further enhance insulation performance and withstand voltage.
4. The outer sheath is the external protective layer of the cable, used to protect it from environmental influences such as chemicals, ultraviolet radiation, and moisture. The outer sheath is typically made of weather-resistant and corrosion-resistant materials such as polyvinyl chloride (PVC) or cross-linked polyethylene (XLPE). Of course, armored high-voltage cables are mainly used for underground burial, capable of withstanding high-intensity pressure from the ground and preventing damage from other external forces.

3.Types and applications of high-voltage cables 

 4.high-voltage cables Use features

Suitable for fixed-lay AC power transmission and distribution lines with a rated voltage of 35kV and below. The maximum long-term operating temperature of the cable conductor is 90 degrees Celsius, and the maximum temperature of the cable conductor during a short circuit (not exceeding 5 seconds) should not exceed 250 degrees Celsius. During operation, voltage fluctuations should not exceed 15% of the rated voltage; otherwise, it will seriously affect the cable. The eccentricity of the insulation layer is a key factor affecting cable performance; insulation eccentricity will lead to electric field distortion, thereby shortening the cable's service life.

5. Application Areas of High-Voltage Cables

1. In the power industry, high-voltage cables serve as the backbone of power transmission and distribution systems, particularly for long-distance grid transmission, urban power distribution, and grid connection of renewable energy generation.
2. In the transportation industry, they are used for power transmission between motors and controllers in electric vehicles such as electric cars and electric trains, as well as for power supply to subway and rail transit systems. In the communications industry, they are used to transmit telecommunications, network, broadcasting, and television signals.
3. In the healthcare industry, they provide high-energy current and high-frequency signal transmission for advanced medical equipment such as MRI and PET scanners.
4. In the industrial sector, they drive large, high-power machinery in industries such as metallurgy, mining, papermaking, and chemicals, and are integrated with automation systems. In the construction industry, they provide stable power support for high-energy-consuming buildings such as airports, shopping malls, and hotels.

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