How to design the electric vehicle wiring harness? What are the design codes and standards?

The design of electric vehicle wiring harnesses is an important engineering task, which involves the wiring and connection of the electric vehicle electrical system, and is critical to the performance and safety of the vehicle. The following will introduce the general principles, design specifications and standards for electric vehicle wiring harness design. Basic principles: safety: the harness design must comply with the relevant requirements of vehicle electrical safety to prevent circuit short-circuit, overload, electromagnetic interference and other issues. Reliability: the wiring harness must have sufficient durability and vibration resistance to cope with the vibration and environmental conditions of vehicle operation. Efficiency: The harness design should minimize the length and weight of the harness to reduce energy loss and improve energy efficiency. Maintainability: Harnesses should have easy maintenance and troubleshooting characteristics to reduce repair time and costs. Design Codes and Standards: ISO 6722: This is an international standard that specifies the physical and electrical characteristics of electrical wiring for vehicles, such as conductor materials, insulation, heat resistance, electrical characteristics, etc. SAE J1128: A standard developed by the Society of Automotive Engineers (SAE) that specifies the requirements for wiring for low-voltage electrical systems, including conductor sizes, resistances, insulation materials, etc. SAE J1939: A standard developed by SAE for communication between vehicle Electronic Control Units (ECUs), defining wiring harness connectors, communication protocols and data transmission formats, etc. GB/T 18384: A Chinese standard that specifies the technical requirements and test methods for wiring harnesses used in electric vehicles, including insulation, heat resistance, and flame resistance. Vehicle manufacturer specifications: Each vehicle manufacturer usually has its own wiring harness design specifications, which are developed according to its product characteristics and needs, such as Tesla's design specifications. Factors to be considered in wiring harness design: Electrical load: According to the electrical system requirements of the vehicle, determine the conductor size and current carrying capacity of the wiring harness to ensure the stable transmission of electrical signals and safety performance. Environmental conditions: Consider the environmental conditions in which the vehicle is located, such as temperature, humidity, vibration, etc., and select appropriate insulating materials and protective measures to ensure the reliability of the wiring harness under adverse conditions.

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