Flexible Structure and Electromagnetic Compatibility Design for High-Power Liquid-Cooled Charging Pile Cables

Research on flexible structure optimization and electromagnetic interference suppression was conducted to address the requirements for flexible operation and electromagnetic compatibility of high-power charging cables in new energy vehicle DC fast charging stations. Through methods including conductor refinement, selection of cross-linked elastomers, multi-layer composite topology design, and thermal insulation and weight reduction design, combined with verification by Abaqus finite element simulation, the goals of a cable bending radius no greater than 10 times the cable outer diameter and a cyclic bending life of no less than 30000 times were achieved. In terms of electromagnetic compatibility, tinned copper braided shielding (with a coverage rate no less than 85%) and 360° circumferential crimping were adopted. Consequently, radiated emission was reduced by more than 25 dBμV·m⁻¹ in the range of 0.03~1 GHz, and a compliance margin of 6~13 dB was achieved. It was indicated by the research results that the optimization scheme could balance flexibility, durability, and electromagnetic compatibility, and the practical demands of fast charging scenarios were satisfied.