New Energy Vehicle Wiring Harness Design and Wire Requirements

The application scenarios of new energy vehicle wiring harnesses mainly include internal wiring, charging guns/charging piles and charging with the vehicle. The in-vehicle high-voltage wiring harness is mainly used to provide high-voltage and strong electrical power for new energy vehicles. It is a high-security component in new energy vehicles, characterized by large voltage/current and a large number of large-diameter wires. This also makes the design of wiring harnesses for new energy vehicles face many challenges. Design and wiring requirements for new energy vehicle wiring harnesses. Typical pure electric vehicle high-voltage wiring harness example 1, the basic characteristics of the vehicle high-voltage wiring harness high-voltage/current new energy vehicle battery voltage can reach 600V, the corresponding conductor voltage withstand level can be up to 300A. traditional fuel vehicle battery voltage is generally 12V, the corresponding conductor voltage withstand level of less than 60V. 2. large diameter wire new energy vehicles need to be in the high-voltage batteries, inverter, transformer, low voltage battery, air-conditioning compressor and other components. batteries, air conditioning compressors, and other components with large diameter wires, and the number is very large.2. Challenges Facing High Voltage Wiring Harnesses in VehiclesDue to the high voltage/current and the large number of large-diameter wires, the design of high-voltage wiring harnesses in vehicles is faced with challenges in terms of safety, wiring, shielding, weight, and cost. In the face of these challenges, we summarize some countermeasures. 1. Safety In the face of safety challenges, some countermeasures should be taken in the selection and sealing of vehicle wires (1) Conductor selection of high-voltage conductor 600V/900V (AC) (refer to ISO19642); the use of wall-thickness elevated wires with a wall thickness of 0.6mm-1.1mm; the use of heat-resistant wires with a heat-resistance of 150 degrees or more can be selected from silicone rubber Conductor and cross-linked polyethylene/cross-linked polyolefin materials

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