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Kable-X was founded in 2015, with a factory area of 5000 square meters and 250 employees. The company has advanced harness processing and testing equipment and more than 20 experienced harness engineers. The company's products cover a wide range of fields, such as Laser Welding Equipment Wiring Harness, BMS acquisition Wire Harness and Power Equipment Wire Harness. The high-voltage harness is also one of the company's best-selling products. Now I will explain the high voltage harness.
The protection structure should be designed when the high-voltage cable has too sharp edges or vias, Avoid the heat source or keep a sufficient distance from it when arranging. Avoid large elastic friction between cables;
Usually, the distance between fixed points of cables arranged in a straight line is ≤300 mm, and the distance between fixed points and connectors is ≤120 mm (reference value).
The motor harness should consider the influence of movement and vibration of components and the influence on connectors or terminals, and reserve enough exercise.
Electromagnetic interference should be considered in Wiring Harness layout, and 90 fold line should be avoided when wiring. High and low voltage lines should be arranged separately.
The layout of high-voltage wiring harness should have suitable space for installation and maintenance.
It will be a trend to reduce the number and material number of the whole vehicle harness. With the modularization and integration of the whole vehicle, the harness will be standardized step by step. Multiple harnesses exist with one material number, which is convenient for management and cost calculation.
The tail of the Connector should be kept straight to avoid the sealing failure of the connector caused by bending.
When wiring, attention should be paid to the separation of high and low voltage, layered design, keeping the distance within 200mm-300m, standardized wiring, and keeping the interference source away from the signal source.
For high-voltage systems, shielding should give priority to the rationality of layout at the system level, such as the separation of high voltage and low voltage, standardized wiring, and keeping interference sources away from signal sources. At the same time, pay attention to the distance between the power source and the output of the high-voltage harness, such as the motor and the motor controller on the whole vehicle. If the arrangement is far apart, the risk of common-mode current transmission interference through the cable will be formed.
For the connector with its own 360 shielding layer, it must be effectively connected with the cable shielding layer. The shielding layer covers the whole connection length to ensure sufficient shielding function and minimize the resistance between the shielding interfaces. During the product life cycle, the contact resistance of the shielding connection is < 10MΩ. With the increasing number of electrical equipment in the whole vehicle, the current general value is < 5mΩ.
In addition, it is necessary to consider the reliable grounding of shielding. If the equipment end is connected by nuts, we need anti-corrosion treatment, because if not, it will lead to increased risk of shielding and effective shielding connection between cables or connectors and the equipment end. If there is no surface protective layer on the surface of the equipment end, we even need to add shielding boxes and other ways to realize reliable shielding continuity connection.
The selection of high-voltage connectors mainly takes into account the electrical principle, application requirements, wiring harness layout, assembly space and assembly method of electrical appliances, and it is also necessary to comprehensively consider the cost. For the integration scheme, via connector can be considered, mainly considering the cost factor and the fear of tripping risk of plug-in connector under vibration. For batteries, motors, etc. that need to be assembled in the vehicle factory, plug-in connectors are usually used; Temperature rise and waterproof grade requirements can be considered for parts with relatively harsh environmental requirements, high environmental temperature and large current and instantaneous current.
reduction of quantity and material number
Materials mainly include core insulation and sheath insulation. The selection of insulation material for wire core is mainly based on heat resistance, mechanical strength and softness, and the selection of sheath material is based on thermal and mechanical requirements. Because the insulation is in direct contact with the environment, the environmental properties such as liquid resistance and wear resistance are particularly important to the requirements of the sheath. At present, cross-linked polyethylene and silicone rubber are the basic materials of insulation layer.
In order to reduce fuel consumption, a large number of wiring harnesses on the whole vehicle have become the key goal of lightening enterprises. At present, copper is the main material used in automotive wiring harness, so in addition to reducing the cross-sectional area, aluminum material lighter than copper is used to reduce weight. In addition, the price of aluminum is cheaper than that of copper. Once aluminum wire can be applied in wire harness, it can not only reduce the weight, but also effectively improve the cost performance.
With the progress of terminal technology, small terminals can carry more current, and the structure of high-voltage connector is developing towards increasingly precision and light weight. The improvement of performance also brings more space for the design of the whole vehicle factory, and the cost will be further optimized.
At present, China's new energy vehicles have just started, the new energy products in the market are mixed, and the standards are not perfect. However, with its rapid development, many newer technologies and products will appear in the market in the future, and with the support of national policies, the whole electric vehicle market in China will enter a more rapid development and standardized track in the future.
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Privacy statement: Your privacy is very important to Us. Our company promises not to disclose your personal information to any external company with out your explicit permission.