High-voltage wire harnesses and characteristics on new energy electric vehicle harnesses

Automotive wiring harness is the main body of the network of automotive circuits, is the carrier of the existence of automotive circuits. The wiring harness is the bridge and link between the electrical components of the vehicle, and is the nervous system of the vehicle's power and signal transmission and distribution. High-voltage wiring harnesses can be configured according to different voltage levels for internal and external wiring harness connections of electric vehicles. It is mainly used for signal distribution of wiring harnesses inside the power distribution box, efficient and high quality transmission of electrical energy and shielding of external signal interference. High-voltage connection system consists of high-voltage wiring harness and connectors. DC/DC, water heater PTC charger, air heater PTC, DC charging port, power motor, high-voltage wiring harness, maintenance switches, inverters, power batteries, high-voltage box, electric air conditioning, AC charging port and so on need to use connectors; high-voltage wiring harness is the neural network of the high-voltage system of new energy vehicles, which is very important.

Since the high-voltage wiring harness is so important, then in the production process to pay attention to what are the main points? Connector temperature rise is high when the safety features will be reduced, or even damaged, resulting in a high temperature rise of the main reasons are two major aspects: 1. Environmental factors: the layout of the location is susceptible to the temperature of the components or in the sealed compartment, such as hybrid exhaust port parts, etc., usually manufacturers of connectors in the operating temperature range of -40 ° C ~ 125 ° C (175 ° C max), so when selecting the connector must be considered when the operating temperature range of value. 2. 2. Connector heating itself: causes connector heating itself for a variety of reasons, we can judge by connecting the program exists in three points: the board end connection point, line end connection point, the middle of the insertion point, which measures the index for the connector between the size of the contact resistance, the smaller the better the contact resistance, meaning that the smaller the electrical loss, the smaller the voltage drop, the terminal can have a higher life expectancy. For the wire section of the crimp, there are often most of the harness factory, crimp good or bad will directly affect the size of its contact resistance, we can not just pull off the force and other conditions in line with the requirements to determine the crimp must be reliable, must be done in detail to the terminal mirror slice test, carefully determine the degree of crimping qualified terminals. For the connection of the board end, usually connected to the high-voltage box or equipment, the connection of the way to the copper row bolt connection mostly, the use of bolt connection is recommended to use the relaxation of the design of the bolts, to prevent the vibration of the condition of the vibration and increase the contact resistance, but also to avoid the electrical connection parts of the load, and at the same time in the bolted connection must be prevented from torque is too large. For the contact of the intermediate insertion and closure point is mainly through the internal contact parts to realize, at present, the contact parts of each family are different, such as open type, crown spring type, torsion spring type, wire spring type, strap type, etc., but we need to consider its insertion and removal life, plating, insertion and removal of the stability of the electrical properties of the technical points, as well as the application of the location and occasions to decide which way is appropriate. For high-voltage systems, shielding should be given priority to systematic consideration of the rationality of the layout, followed by high-voltage cables and high-voltage connector requirements for connectors to have a 360 ° shielding layer, and effective and cable shielding layer connected to the shielding layer covers the entire length of the connection to ensure adequate shielding function and minimize the resistance between the shielding interface, in the product lifecycle, shielding connections contact resistance < 10mΩ.

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