How to choose automotive high voltage wiring harness wire leads?

As the core components of the high-voltage wiring harness of new energy vehicles, the selection of high-voltage wires is very important. The diameter of the conductor shall be preliminarily determined according to the steps, and whether the conductor can be used shall be confirmed in combination with the type and specification of the high-voltage plug-in, especially when it is necessary to calibrate the high-voltage plug-in at both ends, it shall meet the requirements. 1. Wire diameter selection and design considerations: ● Wire design standards, such as LV216-1/2, ISO19642, etc. ● Operating voltage platform and voltage range of the wire. ● Effective operating current of the loop. ● Ambient temperature of high voltage conductor. ● Loop peak current and peak duration. ● Circuit fuse capacity. ● Allowable crimping wire diameter of high voltage harness connector. Basic steps for type selection: 1. Check the working voltage platform of the high-voltage conductor. At present, the voltage platform is generally below 1000VDC, so the high-voltage conductor capable of withstanding 1000VDC is often selected; 2. Select the diameter of the conductor according to the temperature rise curve of the combination of the current-carrying capacity of the conductor and the working ambient temperature; 3. compare that peak current, the peak duration and the smoke curve of the wire, wherein the peak duration is less than the smoke time of the wire; 4. comparing the fuse time and the smoke time of the wire, wherein the smoke time of the wire is greater than the fuse fusing time; 5. Determine the diameter of the conductor preliminarily through the above steps, and combine it with the model and specification of the high-voltage plug-in to confirm whether the conductor can be used, especially when it is necessary to verify the high-voltage plug-in at both ends, it must meet its requirements. 2. Material selection 1. Silicone wire: soft texture, good temperature resistance, but poor tear resistance and oil resistance. The application environment is as follows: ● The working environment temperature is above 150 ℃; ● The harness layout space is small, and the complete radius does not meet the 5D area, or the area with high requirements for harness flexibility due to assembly needs. ● The high-voltage harness is well protected, and there is no oil and no wear parts; ● There are clear requirements for the use of high-voltage connectors. 2. Crosslinked polyolefin line: hard, wear-resistant, tear-resistant, low cost, but poor softness and temperature resistance. The following is the application environment: ● The working environment temperature is not more than 150 ℃; ● The wiring space of this product is very large, the complete radius is not less than 5D, or the wiring harness assembly is not difficult; ● This wire may be in contact with oil, or the wear vibration amplitude is large; ● There are clear requirements for the use of high voltage connectors. 3. If other conductors have flame retardant requirements, HB and V0 grade conductors can be selected; if there are requirements for conductor shielding, unshielded conductors, single-layer shielded conductors and double-layer shielded conductors can be selected. The density of conductor shielding can be determined as required, and generally the shielding density is more than 85%.

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