Design of High-voltage Wiring Harness for New Energy Vehicles

For traditional fuel vehicles, the power source is the combustion of fuel through the movement of the engine piston, relying on the crankshaft and gear train to transmit the power equipment such as the engine flywheel, generator, compressor and cooling water pump, and the driving and functional operation of the vehicle are realized through the power transmission device. For new energy vehicles, especially pure electric vehicles, the power source is provided by high-voltage battery packs, and the transmission carrier is high-voltage wire harnesses, which are connected to high-power equipment such as charging ports, high-voltage battery packs, inverters, motors, on-board chargers, and DC converters. Low-power equipment such as air-conditioning compressors, PTCs, and heaters.
1 Design of high voltage Wiring Harness
1.1 Composition of high voltage wiring harness
The high-voltage wiring harness mainly includes: high-voltage connectors, high-voltage cables, grounding terminals and cable ties, outsourcing materials, tapes, heat-shrinkable sleeves, rubber sleeves, mounting brackets and other auxiliary materials.
1.2 High voltage Connector
According to the function definition, it can be divided into two types: small current and large current. The large current is mainly used for power systems such as OBC, motors, and batteries, and the small current is mainly used for functional electrical appliances such as compressors, PTCs, battery heating devices, and DCDC. .
1.3 High voltage cable
High-voltage cables are mainly divided into two types: shielded and unshielded, with wire diameters ranging from 2.5mm² to 120mm².
1.4 Auxiliary accessories
Auxiliary materials and accessories are not much different from those used in traditional low-voltage wiring harnesses, but the outer material needs to be covered with red or orange-red coverings, so as to play the role of high-voltage danger warning.
New energy vehicle wire harness

2 Technical requirements for high voltage cables
2.1 Technical requirements for cables
(1) Structure
High-voltage cables are mainly composed of cores and insulating materials, and the shielded wires also have a shielding layer and a double-layer insulation structure. The wire core is first bundled by a certain number of monofilaments, and then concentrically twisted to form a soft conductor required for high-voltage cables. According to the structure, it can be divided into shielded wire and unshielded wire, according to the application, it can be divided into single-core shielded wire and multi-core shielded wire.
(2) Insulating material
The wiring needs to consider the aesthetics of the wiring, and it is necessary to consider adding a Wire Harness protection groove for hanging wires on the exposed site.
(3) Shield
Due to EMC (Electromagnetic Compatibility) requirements, multiple copper wires are used to form a braided shield. Tinned copper wire makes it stronger against environmental influences such as oxidation. Using thin copper wire keeps the design flexible, and braided shields can be combined with various other shields, such as aluminum-plastic-conformal films. The shield can be wrapped with a non-woven layer to ensure easy removal of the sheath during assembly.
(4) Bending radius
Due to the limitation of space, the path that the cable passes through is very narrow and complicated, and the cross-sectional area is larger than that of the ordinary wire harness, which leads to a large bending radius, and the high bending force is difficult to overcome. In order to solve this problem, high flexibility of high-voltage cables is crucial, and only a relatively flexible design can be easily achieved for routing through vehicles. Usually 5 to 10 times the outer diameter of the SR wire recommended for the cable.
Kable-X was established in 2015 and the company is located in Suzhou, Jiangsu. The factory covers an area of 5,000㎡ and has about 300 employees. Our company mainly produces and processes industrial control Cable Assembly, Energy Storage Wire Harness, new energy Vehicle Wire Harness and various types of power wiring harnesses. Our wire harness products have always been one of the main reasons for getting high praise from customers, the company has been adhering to the quality policy of guarantee management excellence, keep quality stable and make customer satisfaction. At present, Kable-X's customers are all over the world. If you also have needs, please send your needs to our website mailbox.