Automotive high-voltage wiring harnesses are a type of cable system that has gradually become a key element along with the popularization of automotive technology, especially electric and hybrid vehicles. The following is a detailed introduction to automotive high-voltage wiring harnesses:
I. Definition and Function of HV Cable Harness
High-voltage wiring harnesses refer to cable systems used for transmitting high-voltage power signals and are mainly applied in electric vehicles and hybrid vehicles. These wiring harnesses are usually connected to batteries, inverters and motors to ensure the efficient transmission of electrical energy.
II. HV EV Cable Assembly Composition
High-voltage wiring harnesses are usually composed of the following parts:
1. Conductor: It is usually made of copper or aluminium and has good electrical conductivity.
2. Insulation layer: The key to preventing current leakage and short circuits. Insulating materials are usually cross-linked polyethylene (XLPE) or fluoroplastics, which can withstand high temperatures, are wear-resistant and have excellent electrical insulation properties.
3. Sheath: The outer protective layer of high-voltage wiring harnesses is usually made of materials that are resistant to high temperatures, oil and chemical corrosion.
4. Connector: It is used to connect the wiring harness with devices such as batteries and inverters. High-voltage connectors need to have excellent waterproof, dustproof and shockproof capabilities to adapt to the complex automotive working environment.
III. Characteristics and Requirements
1. Security
The design and manufacture of high-voltage wiring harnesses are directly related to the safety of automobiles. As high-voltage wiring harnesses carry the electrical energy of electric vehicles, once a fault occurs, it may lead to serious consequences such as short circuits and fires. Therefore, strict production standards and inspection procedures are important guarantees for ensuring the safety of high-voltage wiring harnesses.
2. Performance
The performance of high-voltage wiring harnesses affects the overall performance of a vehicle. For instance, the resistance and conductivity of the wiring harness directly affect the efficiency of current transmission, thereby influencing the power output and endurance of the motor. High-quality high-voltage wiring harnesses can effectively reduce energy loss and enhance the overall performance of electric vehicles.
3. Durability
High-voltage wiring harnesses need to withstand various complex environmental conditions throughout the life cycle of a vehicle, such as high temperature, low temperature, humidity, and vibration. Therefore, the material selection and manufacturing process of the wiring harness must have good durability. Durable high-voltage wiring harnesses can reduce maintenance frequency, lower usage costs and enhance consumer satisfaction.
IV. Classification and Layout
1. In new energy vehicles (taking pure electric as an example), high-voltage wiring harnesses can be divided into the following five major parts:
- High-voltage cables for power batteries
- The wiring harness connecting the power battery to the high-voltage box
2. Motor controller cable
The wiring harness connecting the high-voltage box to the motor controller
3. Fast charging wiring harness
The wiring harness connecting the fast charging port to the high-voltage box
4. Slow charging wiring harness
The wiring harness connecting the slow charging port to the on-board charger.
5. High-voltage accessory wiring harness (High-voltage wiring harness assembly)
The wiring harness connecting the high-voltage box to the DC/DC, on-board charger, air conditioning compressor and air conditioning PTC
The layout of high-voltage wiring harnesses for electric vehicles should follow the principle of proximity to minimize the use of high-voltage cables while meeting the requirements of the overall layout and high-voltage electrical design. In addition, it is necessary to pay attention to avoiding potential safety hazards such as electromagnetic interference, leakage of electricity and fire.
V. Notes
1. The layout of high-voltage wiring harnesses needs to comply with a series of safety requirements, such as visual concealment, compliance with safety collision regulations, consideration of ergonomics and ease of maintenance, etc
2. When arranging high-voltage wiring harnesses, it is essential to ensure that drivers, passengers or maintenance personnel cannot directly access the high-voltage wiring harnesses
3. When arranging high-voltage wiring harnesses, special attention should also be paid to avoiding areas with excessive squeezing and vibration amplitudes
In conclusion, automotive high-voltage wiring harnesses are an important component of electric vehicles and hybrid vehicles. Their safety, performance and durability are directly related to the overall performance and service life of the vehicle. Therefore, during the design and manufacturing process, it is necessary to strictly follow relevant standards and procedures to ensure the quality and reliability of high-voltage wiring harnesses.
Commercial vehicle high voltage cable assembly