Due to the rapid growth of vehicle electrification in the automotive sector, many new engineering challenges are emerging. One of these is the issue of fatigue in high-voltage cables of in-wheel motors and an evaluation of this phenomenon. For this purpose, a specialized device for cyclic bending of cables was designed and manufactured, with which samples with different bending radii and evaluated damages on the cables were tested. It was found out that the conductor is the most susceptible to such dynamic fatigue, while the fatigue has a smaller impact on other layers or materials in the cable. It was also discovered that such failure modes are extremely difficult to detect. By conducting numerous tests, it was proved that the bending radius has a significant influence on durability. Based on these findings, guidelines for vehicle cable routing were provided.
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