Top 5 Performance Metrics to Evaluate DC Charging Cables for EVs

This article introduces the main features of DC charging cables and analyzes different standard charging interfaces and their applicability, which will help users make a wise purchase decision.

I. Mainstream DC Charging Standards and Cable Characteristics

1. CHAdeMO Cable: Reliable Charging Performance

CHAdeMO interface has been active in the field of EV fast charging for a long time, and its supporting cable has the following advantages:

1.1 Fast replenishment: High-current charging can be realized, significantly compressing the waiting time.

1.2 Strong adaptability: Compatible with a wide range of brands and models, excellent flexibility.

1.3 Solid connection: unique interface design ensures stable and uninterrupted charging process.

1.4 Excellent safety: Built-in temperature monitoring and fault detection system to effectively prevent risks.

2. CCS cables: a multifunctional solution

Combined charging systems (CCS) are becoming more and more mainstream due to their compatibility and efficient performance:

2.1 Dual-mode support: Simultaneously meets the needs of AC and DC charging, enhancing practicality.

2.2 Higher power: Designed to carry high power transmission, suitable for high-capacity battery models.

2.3 Intelligent communication: supports real-time data interaction with the vehicle to ensure charging accuracy.

2.4 Compatible with old equipment: downward compatible with old models, convenient for system integration.

3. Tesla Exclusive Cable: Built for Extreme Speed

Tesla Supercharger cable is specially designed for Tesla models, with the following features:

3.1 Extreme charging experience: output power up to 150kW or more and minute replenishment.

3.2 Dedicated port matching: Perfectly matching Tesla's unique interface to ensure stable connection.

3.3 High-efficiency heat dissipation system: Even under high loads, the temperature can be kept under proper control.

II. Analysis of the core structure of DC charging cables

Power level and charging efficiency

DC cables generally support an output range of 50kW to 350kW, and some high-end products can withstand higher power. Reasonable power level can significantly reduce charging time and improve overall traveling efficiency.

Interface types and adaptability

The main DC charging interfaces include Type 2 (Mennekes), CHAdeMO and CCS. Users should select the appropriate interface according to the EV interface standard used to ensure compatibility and charging performance.

Material Selection: Conductor and Insulation

Conductor Material: Most DC cables use high purity copper due to its excellent conductivity and low energy loss.

Insulation: Common materials include thermoplastic elastomers (TPEs), PVC and rubber, offering varying degrees of flexibility, temperature resistance and durability.

Heat dissipation and temperature control

High currents during DC charging generate a lot of heat. High-quality cables effectively reduce resistance by increasing cross-sectional area and optimizing conductor layout, thereby controlling temperature rise and improving charging safety.

Durability, safety and environmental protection

Rugged construction: top quality copper core with multi-layer insulation and outer jacket design, anti-stretch and anti-abrasion, suitable for all kinds of harsh environments.

Flame retardant standard: TPE and halogen-free materials have excellent flame retardant ability, which can effectively control the risk of fire spread.

Protection grade: IP54, IP67 and other protection grades provide good dustproof and waterproof ability to ensure the safety of outdoor use.

III. Risk Tips for Extension Cable Use

Although the use of extension cables is more common in household electricity use, the use of extension cables is not recommended in DC fast charging scenarios. Additional wiring may bring voltage drop, power loss, and even cause overheating problems, affecting charging efficiency and electricity safety.

A better solution is to optimize the charging station layout or choose a portable DC charging device.

To improve charging compatibility and flexibility, Nexway EV introduces the CCS2 to CCS1 adapter. This product is suitable for conversion between different standard interfaces, expanding your charging network options and is an ideal aid for pure EV owners.