Selecting the correct type of automotive cable is crucial for ensuring optimal performance and safety for our vehicle. With a wide variety of automotive wires available, it can be challenging to determine the right choice. We will explain the main categories of automotive wire and cables and provide guidance on how to make the selection.
What is an automotive wire?
Automotive electrical wires are the backbone of a car electrical system. Wires are built to withstand the harsh environments inside a car. Auto wires are usually made of copper or aluminum and come in a variety of sizes. Automotive wire insulation types commonly include durable materials like PVC and XLPE, powering key components such as headlights, ignition systems, and fuel pumps.
What types of wires are used in automotive?
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Classification Based on Insulating Material
1. PVC automotive wire
PVC automotive wires are widely used in the automotive industry due to their durability, flexibility, abrasion resistance and chemical resistance. Its rugged construction provides reliable performance for critical components.
PVC primary wire for automobiles comes in a variety of forms: GPT Wire,TWP Wire, HDT Wire
- For general circuit wiring and trailer wiring, GPT wire is ideal. this standard wall wire offers excellent weather resistance. It performs well in temperatures ranging from -40°C to 85°C and is suitable for a variety of automotive conditions.
- TWP wire is a lightweight, thin-walled wire rated up to 105°C that is durable and versatile for a variety of applications.
- HDT wire is a thick-walled wire designed for heavy applications. It can withstand the usual physical wear on the surface of the wiring, with a set temperature of up to 85°F.
2. Cross-link automotive primary wire
It has greater heat resistance, durability and abrasion resistance due to the cross-linked polyethylene insulation. The majority of cross-linked automotive raw wire can be used in high temperature areas such as engine compartments. It is ideal for long-lasting and reliable performance in automotive applications.
There are three types of wire that make up cross-link automobile primary wiring: GXL Wire, SXL Wire, TXL Wire
- GXL wires have a thin-walled design and are lightweight and heat resistant up to 125ºC.
- SXL wire has a standard wall with excellent heat and abrasion resistance. It works effectively in temperatures ranging from -40°C to 125ºC.
- TXL wire stands out with its ultra-thin walls, high heat resistance and flexibility. It is especially beneficial in tight spaces and at low temperatures, where it maintains its performance over a temperature range of -40°C to 125ºC.
Comparison of different wires for automotive primary wire
| Wire Type | Temperature Rating | Insulation Material | Applications | Flexibility | Price Range |
|---|---|---|---|---|---|
| GPT Wire | -40°C-80°C | PVC | General automotive use | Moderate | Low |
| TWP Wire | -40°C-105°C | PVC | Wiring in wet environments | Moderate | Moderate |
| HDT Wire | -40°C-125°C | PVC | High-temperature areas | Good | Moderate to High |
| GXL Wire | -40°C-125°C | Cross-linked Polyethylene | High-performance wiring | Excellent | Moderate to High |
| SXL Wire | -40°C-125°C | Cross-linked Polyethylene | Heavy-duty applications | Excellent | High |
| TXL Wire | -40°C-150°C | Cross-linked Polyethylene | Ultra-flexible wiring | Superior | High |
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Classification Based on voltage level
1. High-voltage wires: These wiring harnesses are mainly used in new energy vehicles. With a voltage of 300V and above, it is responsible for driving the transmission of electricity and securing the energy supply of high-power devices such as electric motors.
2. Low-voltage wires: This kind of cable usually has a voltage below 60V and is suitable for the low-voltage system of traditional fuel vehicles and some new energy vehicles.
In terms of material and structure, both high-voltage and low-voltage wires tend to use copper multi-core soft wire to enhance its flexibility and durability. In addition, the selection of wire cross-section area is based on the working current, to ensure that the voltage loss is within the permissible range, for high-current equipment such as starter motors, the cross-section area of the wire will be larger, while for small-current electrical appliances, to ensure that they have the necessary mechanical strength.
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Classification Based on Structural Design
1. Single core unshielded: the most common type and used for general signal transmission.
2. Single core shielded: It reduces electromagnetic interference and is suitable for electronic signal transmission.
3. Multi-core unshielded and multi-core shielded: It is used where higher signal integrity is required.
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Classification Based on Type and Standard
1. National Standards (e.g. QVR-105): This standard is designed for automotive wiring applications in the Chinese market. It ensures that the cable meets the stringent safety and performance standards required for automotive use.
2. Japanese Standards (AV, AVS, AVSS, etc.): These specifications are characterized by thin insulation, which not only reduces the overall weight of the wiring, but also increases flexibility. This makes them ideal for modern automotive designs.
3. German standards (e.g. FLRY): This specification is also characterized by thin-skinned insulation and excellent flexibility. It meets the growing demand for efficient, flexible automotive structures.
4. American Standard: This category offers options such as high temperature resistance and specialized elastomer insulation designed to cope with extreme conditions and extend wiring life.
In addition, a range of different specifications such as AVSS, CAVUS, AV, AVSSH-AVSSX-AESSX, and AVX-AEX are available for different environments and requirements such as high-temperature-resistant, ultra-fine, or normal wires. Automotive wiring must be chosen depending on the insulation type, voltage rating, structural layout, and adherence to industry norms.
Moreover, extreme temperatures, vibrations, oils, and chemicals are just a few of the harsh conditions that can exist in an automobile. While automotive cables are designed to handle more extreme temperatures and is safe to use in a car, household wiring is definitely not. Therefore, we need to be careful not to use regular household wires for automobiles!
So, pick the right automotive cable type that fits your needs to keep your vehicle running smoothly for a longer time! At ZW cable, we are committed to providing you with the best wire for automotive use and more optional automotive wire gauge, so if you are unsure about the right type for your purchase, feel free to contact one of our professional representatives.
