Conventional Application Harnesses vs. Automotive High Voltage Harnesses

China [CN]

There are some differences between high-voltage cables of new energy vehicles and ordinary automotive cables, mainly because the application environment has changed greatly, such as high voltage and high current (on-board), wire diameter (large number of cables; on-board), and exposed space (outside of the vehicle).

Detailed introduction of high-voltage cables of new energy vehicles and ordinary automotive cables: The high-voltage cables used in new energy electric vehicles can reach 600/300A, but the batteries of traditional fuel vehicles are usually 12V, and the corresponding wire withstand voltage level is less than 60V; connecting the high-voltage battery inverter transformer/low-voltage battery/air conditioning compressor/electric heating/power distribution unit on the vehicle, many electrical structures are connected with cables, and huge cables are configured in a limited space; however, the cables of the charging gun part are in the exposed space for a long time, and there are strict requirements for weather resistance, wear resistance, bending resistance, tear resistance... Because the high-voltage wiring harness in the car has the characteristics of high voltage/high current, large wire diameter and large number of wires, the design of the wiring harness faces challenges such as wiring, safety, shielding, weight and cost.

Regarding the wiring harness design, the wiring can be arranged under the vehicle as much as possible, and the wires should be tough wires such as silicone rubber wires and flexible cross-linked polyolefin wires; safety is particularly important for high voltage and high current. In addition to the strict requirements on insulation performance of the high voltage itself, the high temperature caused by high current is also a must-consider; in order to achieve a good sealing effect, with high-voltage connectors, the seals meet the requirements of waterproof and dustproof (IP67, IP69k), and the wires are required to have dimensional stability, good roundness, and aging performance; Regarding shield, the reason why high-voltage harnesses need electromagnetic shielding is the electromagnetic field noise caused by the high AC current of the high-voltage box and the electromagnetic interference caused by the rapid power-on and power-off drainage of electrical components.

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