What are the quality requirements for electric vehicle wiring harnesses? How to carry out the relevant tests?

Electric vehicle wiring harness is one of the most important components in the electric vehicle. It is responsible for gathering all kinds of electrical signals, power and data transmission lines together to connect the various systems and components of the electric vehicle. Therefore, the quality requirements of electric vehicle wiring harness are very important, which directly affects the performance, reliability and safety of electric vehicles. The following will introduce the quality requirements of electric vehicle wiring harness and related test methods in detail. Harness quality requirements: 1.1 Electrical performance: The conductivity of the harness must meet the design requirements, including conductivity, current carrying capacity and voltage level. The wiring harness shall be capable of stably transmitting power and signals within the normal operating range of the electric vehicle. 1.2 Insulation performance: The harness shall have good insulation performance, which can effectively isolate and protect wires and signal lines to prevent electrical short circuit and leakage. Insulation materials shall comply with relevant standards, such as high temperature resistance, moisture resistance, chemical corrosion resistance, etc. 1.3 Durability: The harness shall have good durability, be able to withstand the impact of environmental factors such as vibration, temperature change and mechanical stress during long-term operation of the electric vehicle, and maintain stable performance and connection state. 1.4 Anti-interference: The wiring harness shall have certain anti-interference performance, which can prevent the influence of external electromagnetic field interference on the electrical signal, and ensure the normal communication and data transmission between the systems and components of the electric vehicle. 1.5 Safety: The wiring harness shall comply with relevant safety standards to avoid electric vehicle accidents and fire risks caused by wiring harness problems. For example, special insulation materials and designs should be used in high-voltage wiring harnesses to ensure the safety of high-voltage lines. Relevant test methods: 2.1 Electrical performance test: verify whether the conductivity of the harness meets the design requirements by testing the resistance, capacitance, inductance and other parameters of the harness. Test equipment such as multimeter and bridge can be used for testing. 2.2 Insulation performance test: evaluate the insulation performance of the harness through insulation resistance test, insulation voltage test and other methods. Commonly used test equipment includes insulation resistance tester, insulation withstand voltage tester, etc. 2.3 Durability test: conduct vibration test, temperature cycle test and tensile test on the harness to evaluate the durability of the harness by simulating the environmental conditions such as vibration, temperature change and mechanical stress of the electric vehicle running for a long time. 2.4 Anti-interference test: conduct electromagnetic compatibility test on the harness by simulating the external electromagnetic field interference. Test methods include radiated immunity test and conducted immunity test. 2.5 Safety test: assess the safety of the material, structure and connection mode of the harness to ensure that the harness meets the relevant safety standards. For example, insulation performance test and high voltage withstand test are carried out for high voltage wiring harness. The above is a brief introduction to the quality requirements of electric vehicle wiring harness and related test methods. The electrical performance, insulation performance, durability, anti-interference, safety and other aspects of the quality requirements of the electric vehicle wiring harness need to be comprehensively considered, and verified through the corresponding test methods, so as to ensure that the wiring harness can stably and reliably transmit power and signals in the normal operation of the electric vehicle, and at the same time ensure the safety performance of the vehicle.

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