Electric vehicle high-voltage wiring harness—the carrier of power transmission

China [CN]

High-voltage wiring harness is the carrier of power output of electric vehicles and a key component that affects the performance and safety of the vehicle. In order to avoid accidental contact and short circuit, new energy vehicle wiring harnesses should be insulated. The inner core of the wiring harness wires is mostly made of copper wire, because copper has small resistance and strong plasticity.

The automotive high-voltage wiring harness is a communication bridge between automotive control components, control units, and execution units. It is the carrier of automotive energy and various signal transmissions, and is the nervous system of the automotive.

The high-voltage wiring harness of new energy vehicles has a high voltage, and the risk of injury to the human body when accidentally touching is also high. In order to prevent voltage leakage, the high-voltage wiring harness needs to be designed with greater insulation. There are usually stickers with various symbols affixed to the interior of the vehicle, and bright orange insulating material is used to warn of hazards.

The wiring harness needs to carry higher power, which means it carries more current. Therefore, the wire diameter of high-voltage wire harnesses is generally designed as copper cables, and the outer diameter is thick and thick.

The current of high-voltage system components is usually 250A, and some high-power motors have higher currents. Generally, the greater the current, the more heat is generated, which also means that high-voltage wire harnesses have requirements for temperature resistance. Conventional high-voltage wire harnesses have a temperature resistance of -40°C to 150°C.

The interior of the car is affected by electromagnetic interference from high voltage and large current. Electrical components will produce a large amount of electromagnetic interference. The entire high-voltage system of the car needs to be covered with a shielding layer. Usually, the high-voltage wire harness is designed into a shielded structure and is then crimped through plug-ins, etc. The structure is connected to the battery motor controller housing, and then connected to the body ground.

To learn more about EV harness information, Please visit or search: https://www.omgevcable.com