Application scenarios and design requirements for new energy wiring harnesses

The wiring harness on the car is particularly large, electronic control systems and wiring harnesses have a close relationship. Someone once played an image analogy: if the microcomputer, sensors and the function of the executive element with the human body to compare, it can be said that the microcomputer equivalent to the human brain, sensors equivalent to the sensory organs, the executive element equivalent to the motor organs, then the wiring harness is the nerve and blood vessels.

The main application scenarios of new energy wiring harness are in-vehicle wiring ( BMS wire speed , and Battery pack in-wire harness , and Main control harness ), charging gun/charging pile and with the car charging three cases, and the in-vehicle high-voltage wiring harness is mainly for new energy vehicles to provide high-voltage strong power supply role, in the new energy vehicles belong to high security parts, with large voltage / high current, large wire diameter wire quantity and other characteristics, which also makes the design of the new energy vehicle in-vehicle high-voltage wiring harness is facing a lot of challenges. Today, we will learn about the new energy vehicle wiring harness design and wire requirements.

 A. Basic characteristics of high-voltage wiring harness in the car

1. High voltage / high current

The battery voltage of new energy vehicles can reach 600V, corresponding to a wire voltage rating of 300A, while the battery voltage of traditional fuel cars is generally 12V, corresponding to a wire voltage rating of less than 60V.

2. Large wire diameter conductor quantity

New energy vehicles need to use large diameter wires in high voltage batteries, inverters, transformers, low voltage batteries, air conditioning compressors, etc. The number of wires is very large.

B.the challenges facing the high-voltage wiring harness in the car

Due to the characteristics of high voltage/high current and large number of wire diameter wires in the vehicle, the design of the wiring harness faces challenges such as safety, wiring, shielding, weight and cost, etc. In the face of these challenges, we have summarized some countermeasures.

1. Security

In the face of security challenges, the choice of wires in the car, sealing and other aspects need to make some response measures

2. Wire selection

Use of high voltage conductors 600V/900V (AC) (refer to ISO19642);

Using wall thickness high line with wall thickness of 0.6mm - 1.1mm;

Heat-resistant wire, heat-resistant 150 degrees or more

Silicone rubber conductors, cross-linked polyethylene/cross-linked polyolefin materials are available