What is a new energy vehicle high voltage wiring harness?

The overall automotive wiring harness can be divided into two types of low-voltage wiring harness and high-voltage wiring harness, traditional fuel vehicles mainly use low-voltage wiring harness, new energy vehicles mainly use high-voltage wiring harness, high-voltage wiring harness can be configured according to the different voltage levels of the electric vehicle internal and external wiring harness connection. The main application of the distribution box internal harness signal distribution, high efficiency and high quality transmission of electrical energy, shielding external signal interference, etc., high-voltage wiring harness is a new energy vehicle high-voltage system of the neural network, is very important, today we talk about what is a new energy vehicle high-voltage wiring harness? New energy vehicle high voltage wiring harness is mainly composed of connectors, terminals, wires, covers and other parts. New energy vehicle high-voltage wiring harness can be configured according to different voltage levels for electric vehicle internal and external wiring harness connection. It is mainly applied to distribution box internal wiring harness signal distribution, efficient and high-quality transmission of electrical energy, shielding external signal interference. Due to the high voltage wiring harness inside the vehicle is characterized by high voltage/high current, large number of conductors with large wire diameter, etc., the design of wiring harnesses is faced with challenges such as wiring, safety, shielding, weight and cost. High-voltage connectors are currently based on industry standards; from the standards of safety, performance and other requirements of the standard, but also test standards, the mainstream design of the current connector manufacturers will basically refer to the four major European OEMs: Audi, BMW, Daimler, Porsche jointly formulated the industry standard LV series of standards; in North America is mainly to come to their own SAEuscar related standards, uscar itself does not draft the Standards, we often use uscar2, 37 and other related standards are mainly from Chrysler, Ford, General Motors three major U.S. OEMs joint wiring harness connection organization EWCAP, this organization has been established in 94 years, in 08 years in order to adapt to more and more of the requirements of the HEV, the organization has updated the SAE-USCAR 2, will be the voltage level from the original 20V to the original 20V to upgrade to the 600V that we see now. For Europe basically is basically by the European Troika (VW BMW Daimler) OEMs jointly developed, as a car big brother of Germany in the development and promotion of its standards also played a very important role, of course, VW in the relevant industry standards inside the interests of the embodiment of the show, for the AK working group, and even refine the installation interface size and other requirements, which also basically meets the requirements of the European and American OEMs. This is basically in line with the consistent style of European and American OEMs, and TE Amphenol, Kostal, molex, delphi, etc. have also joined these standards. For GB, we also released our own high-voltage connector standards, but the standard content, many places still need to further improve and enhance, not to do more here; because high-voltage connectors are generally not possible to appear in the form of a separate product in the vehicle, are generally required to carry cable, so the standard requirements of its wiring harness is also very important, the industry generally refer to SAE j1742 will be more.

High-voltage connector types of new energy vehicles with high-voltage connectors are mechatronic products, mainly by the contact, insulator, shell and accessories composed of four parts, of which: the contact is the connector to complete the optical and electrical signal connection of the core components, through the contact insertion and closure to complete the vehicle in the vehicle in the required optical and electrical signal connection; insulator and shell is mainly played a role in the fixation, insulation and mechanical protection. Manufacturing process set of electrical performance design, CNC machining, stamping technology, plastic pressure technology, precision die-casting technology, strict test methods and other multifaceted technology combinations in one. As the quality and precision of high-voltage connector products directly affect the connector's electrical, mechanical, environmental and other properties, which in turn affects the safety of electric vehicles, so the quality requirements of high-voltage connectors and manufacturing precision is relatively high, belonging to the connector field of high value-added high-end products. We often see a variety of high-voltage connectors on the vehicle, high-voltage connector structure generally includes: contact pairs, seals, docking locking mechanism, bracket, shell, positioning mechanism, high-voltage interlocking mechanism, shielding mechanism, insulation structure and so on. General termination methods include welding, crimping, through-hole connections, screw connections, etc. Installation methods are also diverse, including panel type, cable type, nut type, through the wall, etc. which according to the wiring harness connection method is different, we will mainly be divided into two categories of connection: a bolt directly connected to the fixed type; a plug-in connection. Bolt connection is a connection we often see in the car, the benefits of this way lies in the reliability of its connection, the mechanical force of the bolt is able to withstand the impact of automotive-grade vibration, and its cost is relatively inexpensive, of course, it is inconvenient to bolt connection is the need for a certain amount of space for the operation of the installation, for the area is more and more platform, more and more reasonable space in the car, is not able to leave too much space for installation. And from the perspective of batch operation and after-sales maintenance is also not suitable, and the more bolts the more risk of human error, so it also has its limitations; in the early Japan and the United States hybrid models we often see similar products, of course, now in some passenger cars, three-phase motor lines and some commercial vehicles, battery power input and output lines we can still see a lot of similar connections, this kind of This kind of connection generally need to use the external box to realize the protection and other functional requirements, so whether to use this way need to be from the perspective of the whole vehicle power line design and layout combined with after-sales requirements. High-voltage connector selection and future market expectations of high-voltage connector selection, generally based on the actual need for the use of high-voltage connector selection is a key issue for designers to consider, the following new energy vehicles use scenarios for the selection of high-voltage system according to the vehicle's high-voltage system planning for the selection of high-voltage systems, including power batteries, motors/motor controllers, PDUs, DC or AC Charging system, electric heating, electric air conditioning, DCDC and other electric accessory systems. Firstly, determine the electrical principle of the whole vehicle high voltage, initially clarify the voltage platform of the whole vehicle, as well as the amount of power used/distributed by each equipment, and determine the size of the current-carrying capacity. Secondly, according to the actual layout of the electrical equipment, to determine the use of single-core or multi-core connectors. According to the installation conditions for the selection of high-voltage system on the vehicle is usually more compact installation space, high-voltage equipment structure requires compact and beautiful, and at the same time need to be based on the vehicle's high-voltage wiring harness on the specific direction of clear high-voltage connector form. According to the applicable environment and performance requirements for selection need to confirm the electrical properties of the high-voltage connector, mechanical properties and environmental performance to meet the requirements of the actual vehicle operating conditions and system safety requirements, etc., to determine the selection of products to meet the relevant technical indicators of new energy vehicle development today, more and more new energy vehicles into our lives, whether it's a supercharged electric vehicles, hybrid electric vehicles, fuel cell electric vehicles, hydrogen Engine cars, pure electric vehicles, or other new energy vehicles, etc., need a large number of connectors, and traditional fuel vehicles are different from electric vehicles tend to have higher voltage and current platform, so new energy vehicles often have a large number of high-voltage connectors, the international market, the connector market leader is mainly occupied by the United States, Germany, Japan, France, four countries and regions, basically has formed an oligopoly competition pattern. Formation of oligopoly competition pattern. China's connector after years of technical accumulation, as well as in the new energy vehicle layout in advance, whether in the design capacity or automation production capacity, has to meet the new energy vehicle connectors required by the technical level. In the downstream manufacturers of localization and accumulation of technical capabilities enough to meet the premise of the two conditions, the domestic manufacturers have occupied the new energy vehicle connectors of the high point, in this new field to achieve the corner, breaking the monopoly of foreigners in the traditional automotive connectors. Vehicle manufacturers of high-voltage connector safety, stability, anti-interference, etc. has a strict assessment of time (generally 2-3 years), once the two sides to establish a cooperative relationship, vehicle manufacturers are usually not easy to change their supporting parts suppliers, market share is also more stable. At present, the domestic high-voltage connector manufacturers can supply in bulk: AVIC photoelectric, Yonggui electrical appliances, Jiangsu Ruikoda and a few other companies, in recent years, the second line of business has also begun to grow up, from the point of view of the scale of sales, the domestic market, the Chinese enterprises are also gradually rising. Wave of automotive electrification to promote the demand for high-voltage connectors burst of new energy wiring harness crimp terminals Introduction:Terminals are the foundation, there is no reliable terminals, there is no reliable system engineering. Prevention and analysis is a necessary process for each enterprise, through the reliability of the terminals screening to find a variety of failure modes and failure mechanisms, can analyze a large number of lessons learned and exclude a variety of hidden dangers for the improvement of the design, process, inspection and use of the scientific basis for revising and formulating the technical conditions of the terminals is an important basis for the prevention of unnecessary losses to provide a technical guarantee.

Terminals from the point of view of the use of the function should be achieved is: the contact part of the conductive place must be conductive, reliable contact. Insulation parts should not lead to the place must be insulated reliably. Terminals common fatal failure in the form of the following three: 1. poor contact problems inside the terminal metal conductor is the core parts of the terminal, it will come from the external wire or cable voltage, current or signal transmission to its matching connector corresponding to the contact parts. Therefore, the contact must have excellent structure, stable and reliable contact holding force and good electrical conductivity. As a result of the structural design of the contact parts is not reasonable, the material selection error, mold instability, processing size is too poor, surface roughness, heat treatment plating and other surface treatment process is not reasonable, assembly is not appropriate, storage and use of poor environmental and operational use of improper, will be in the contact parts of the contact parts and with the parts caused by poor contact. 2. poor insulation of the problem of the insulator's role is to make the contact parts to maintain the correct position of the arrangement, and make the Contact parts and contact parts, contact parts and shell insulation between each other. Therefore, the insulator must have excellent electrical properties, mechanical properties and process molding performance. Especially with the high-density, miniaturized terminals are widely used, the effective wall thickness of the insulator is getting thinner and thinner. This insulating materials, injection mold precision and molding process put forward more stringent requirements. Due to the insulator surface or internal presence of metal excess, surface dust, solder and other contaminants damp, organic material precipitates and harmful gases adsorption film and the surface of the water film fusion to form ionic conductive channels, moisture absorption, mold, aging of the insulating material, etc., will cause short-circuiting, leakage, breakdown, low insulation resistance and other insulation defects. 3. poorly fixed problem insulator not only plays an insulating role, usually also for the Extend the contact parts to provide accurate centering and protection, but also has the function of installation and positioning, locking fixed in the equipment. Fixed poorly, the light impact on the contact reliability caused by instantaneous power failure, the serious is the product disintegration. Disintegration refers to the terminals in the state of insertion and closure, due to materials, design, technology and other reasons leading to unreliable structure caused by the plug and socket between the pins and jacks of the abnormal separation, will cause the control system of power transmission and signal control interruption of the serious consequences. Due to unreliable design, wrong material selection, improper selection of molding process, poor quality of heat treatment, molds, assembly, fusion bonding and other processes, assembly is not in place and so on will cause poor fixing. In addition, due to plating peeling, corrosion, bruising, plastic shell flying edge, rupture, contact parts processing roughness, deformation and other reasons caused by the appearance of bad, due to the positioning of the locking with the dimensions of the excessively poor, poor consistency of quality of processing, the total separation force is too large and other reasons caused by the poor interchangeability, but also a common disease, the occurrence of disease. These kinds of faults can generally be found in the inspection and use of the process of timely removal. How to detect terminal short-circuit fault wire and terminal failure may also be due to the wiring harness and the body (ground) between or in the relevant switch internal short circuit caused by. Before checking should first look at the body of the terminal is fixed firmly, and then can be tested according to the following steps.1, check the wire through the first remove the control computer ECU and the sensor on both sides of the terminal, and then measure the resistance of the terminal between the corresponding terminals. If the resistance value is not greater than 1 ohm, it means that the wire is normal, in order to carry out the next check. In measuring the resistance of the wire, vertical and horizontal two directions to gently shake the wire to improve the accuracy of the measurement, while paying attention to most of the wire terminals, multimeter stick should be inserted from the back end of the connector, but for the waterproof terminal equipped with a waterproof sleeve of the waterproof terminal stick can not be inserted from the back end, because when inserted a little bit of carelessness will deform the terminals. 2, short-circuit resistance value check first remove the control computer ECU and sensors on both sides of the wire terminals, and then measure the resistance between the connectors on both sides of the terminal row and the body. Measurement, one end of the meter stick hitch connected to the body, the other end to be measured on both sides of the wire connector, if the resistance value is greater than 1 ohm is an indication of the wire and the body of the short-circuit fault. 3, the appearance of the terminals and the contact pressure check first should be one by one to remove the terminals, check the connector terminals with or without rust touching and dirty, on the corrosion and dirt should be cleaned up. Then check whether the terminal piece is loose or damaged, the terminal is fixed firmly, in the gently pulling the terminal should be no loose phenomenon. On the contrary, if the plug terminal in which seat hole is easier to pull out than other seat holes, the seat hole may cause poor contact failure in use. Introduction to Wires for New Energy Harnesses:The type of wire used for automotive harnesses is affected by the environment and function in which the harness is used. For example, the environment around the engine and power battery is characterized by high ambient temperatures and many corrosive fluids and liquids. Therefore, high-temperature, oil, vibration, and friction-resistant wires must be used; wires on the lid of the compartment must maintain their elasticity at low temperatures, so cold-elastic wires must be used to ensure their normal operation; wires on the automatic transmission must be resistant to high temperatures, hydraulic oil, and have good temperature stability; shielded wires must be used for weak-signal sensors, such as shock sensors and crankshaft position sensors, and ABS wheel speed sensors; and the inside door wires must resist bending; the inside door wires must resist bending; and the inside door wires must resist bending. The wiring harnesses of automobiles often use conductors that are shielded, such as shock sensors and crankshaft position sensors, ABS wheel speed sensors, and so on. The wires used in automotive wiring harnesses are usually multi-stranded copper wires insulated with PVC insulation. The wires used for wiring harnesses must be resistant to temperature, oil, abrasion, water, corrosion, oxidation, and flame retardant. Currently, the main types of wires used by domestic automobile brands include Japanese Standard (DSD) wires and German Standard (DSD) wires. Conventional automobiles are powered by gasoline engines, and conventional automotive wires are used for transmitting control signals and are subject to very low currents and voltages, resulting in small wire diameters and simple structures consisting of a conductor and insulation. Therefore, the wire diameter is small and the structure is simple: just conductors with insulation. However, according to the requirements for the use of high-voltage cables in electric vehicles, high-voltage cables are mainly used for energy transmission, and need to transmit the energy from the battery to various sub-systems. Therefore, the high-voltage wiring harnesses designed for electric vehicles must be adequate for high-voltage and high-current transmission. Since the high-voltage cables of electric vehicles are subjected to high voltages (rated voltage of 600 V), high currents (rated current of 600 A), and strong electromagnetic radiation, the diameter of the cables is significantly enlarged, and in order to avoid any strong electromagnetic interference with surrounding electronic equipment, which could affect the normal operation of other electronic equipment, the cables are designed with a shielding structure to prevent any electromagnetic interference, which means that they are coaxial in structure and utilize both the inner and outer conductors (shielding). By using a coaxial structure that utilizes both the inner conductor and the outer conductor (shielding), the magnetic field inside the cable is distributed identically so that the electric field is directed from the inner conductor to the outer conductor, resulting in zero electromagnetic field around the cable, or shielding against electromagnetic radiation, and thus ensuring the normal operation of electric vehicles. In the early days, automotive cables were mainly insulated with PVC (polychlorinated vinylidene), but PVC contains lead, which is harmful to the human body, and in recent years it has been gradually replaced by LSZH (low-smoke, no-halogen materials) TPE (thermoplastic elastomers), XLPE (cross-linking polyvinylidene), and silicone rubber, among others. As the high-voltage cable of electric vehicles meets the requirements of high voltage and high current, anti-electromagnetic interference and abrasion resistance and flame retardancy, compared with these materials, silicone rubber has a high breakdown voltage, arc resistance, resistance to leakage traces, ozone resistance, and at the same time, it has a good resistance to high and low temperatures, good insulating properties, stable performance at high temperatures and high humidity, flame retardancy, and so on, and the combination of physical and mechanical properties of the silicone rubber, long life, low price, and so on. The combination of good physical and mechanical properties, long service life, and low price makes silicone rubber the high-voltage cable insulation material of choice for electric passenger vehicles today; in general, high-voltage cables are now mainly made of cross-linked polyurethane (XLPE) or silicone rubber cables. XLPE is the main material used by domestic manufacturers, and because XLPE technology is more mature, manufacturers can add cross-linking masterbatch to it for direct production at a lower cost and time. Silicone rubber cables, with their high resistance to high temperatures (-50°C-180°C) and flexibility, are very useful for wiring in cars, and silicone cables are not very common in China due to the ratio of the synthesis of silicone rubber materials and the optimization of the manufacturing process. The following is an outline of the current classification of high-voltage cables.1. By voltage level: 600V, 1000V, 1500V, 3000V; 2. By temperature level: 125°C, 150°C, 180°C, 200°C; 3. By insulation properties: thermoplastic insulation and thermoset insulation; 4. By shielding type: shielded and unshielded cables; 5. By the number of insulated cores: Multi-core and single-core cables; 6, cable square number: 1.25, 2, 2.5, 3, 4, 5, 10, 16, 25, 35, 50, 70, 95, 120 and so on. Covering-covering the introduction of:Bellows, the general material for the PA / PP, temperature in -40 ° C -125 ° C, mainly effective protection of the role of the cable. Heat-shrinkable tubing, generally made of polypropylene, temperature resistance at -40°C-125°C, soft and flexible, applied to a variety of wire harnesses, solder joints, inductors, insulation protection. Analysis of the development trend of the automotive wiring harness industry At present, the global automotive wiring harness enterprises are mainly divided into four echelons, the first echelon of Yazaki and Sumitomo Electric, the second echelon includes Ampofo, Leni and Lear, the third echelon includes Dekosmil, Kromberg & Schubert, Furukawa Electric, Yuro, Kyoshin, Fujikura, and the fourth echelon includes other small wiring harness enterprises. At present, the global automotive wiring harness market is mainly occupied by the first three echelons, and the world's major automobile manufacturers to form a solid supporting system. At the same time, due to the great potential for development of China's wiring harness market, the international wiring harness manufacturers mainly through acquisitions, sole proprietorships or joint ventures with local enterprises in the way of layout of the Chinese market, with joint ventures and local car manufacturers supporting. China's automotive wiring harness enterprises mainly include Hukuang shares, Tianhai Group, Delun Electronics, Shanghai Jinting (Yongding shares), Mandel Electronics, Lixun Precision, Qiaoyun Electronics, Huakai Harness, Koboda and so on. With the growing localization of auto parts procurement, some local wiring harness enterprises, through the long-term accumulation of product technology and synchronization of development experience, the overall strength has increased significantly, by virtue of timely and effective service, reliable product quality and gradually enter the international automobile manufacturers of the supplier supporting system. Such as Tianhai Group, Hukuang shares, Shanghai Jinting, Delun Electronics, Koboda and so on. With the growing richness of automotive features, the demand for automotive wiring harness has also grown significantly, which directly leads to the length and weight of the automotive wiring harness greatly increased, resulting in a substantial increase in the weight of the car, and the wiring harness wiring difficulty greatly increased, so it must be optimized from the quality of the wiring to the automotive wiring harness, to meet the demand for the booming growth. We believe that the automotive wiring harness will be mainly to the following aspects of development: First: the automotive wiring harness market lightweight is the main tone of the future development Second: FPC program is commonly used in mainstream electric car models, FPC alternative to the traditional wiring harness into the trend of the third: automation, the topic will soon be released to sort out the complex structure of the automotive wiring, 95% of the wiring harnesses need to be hand-made at present, the production is inefficient, and it is a typical Labor-intensive industry, labor costs have become a constraint on the expansion of production capacity, one of the main factors to achieve the effect of scale. At present, most of the automotive wiring harness manufacturers are still stuck in relying on local advanced equipment to complete some of the processing aspects of automated production stage, intelligent manufacturing has not yet popularized the development. With the gradual integration of automotive wiring harnesses in the future, as well as the continuous progress of production technology, intelligent manufacturing is expected to be realized through the automotive wiring harness design, production, warehousing, logistics, management and service and other processes. At present, including Ampofo, Lear, Hukuang shares and other automotive wiring harness enterprises are promoting automation of automotive wiring harness production process.

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