High-voltage wiring harness design

High-voltage wiring harness design is a key part of the electrical system of electric vehicles, which is related to the overall safety of vehicles and people. In this article, we will explore the three main aspects of high-voltage wiring harness design: line protection design, high-voltage cable selection, and high-voltage wiring harness wrapping and fixing methods.

1. Line protection design Line protection design is an important part of high-voltage wiring harness design. Its main purpose is to prevent circuit overload and short-circuit faults. In electric vehicles, line protection design usually uses high-voltage fuses as protection measures. High-voltage fuses can quickly and safely disconnect the circuit channel to prevent short-circuit fault current from directly impacting the battery or high-voltage input module. According to the national standard GB/T 18384.2-2001 "Safety Requirements for Electric Vehicles", when the current is too large, a circuit protector, disconnection device or fuse should be used to disconnect the on-board power supply. Therefore, using fuses to protect electric vehicle power batteries is not only a fuse with many advantages, but also an effective measure recognized by international standards, and it is also an indispensable and necessary means clearly stipulated by national standards. 2. High-voltage cable selection High-voltage cable is a key component in high-voltage harness design. It requires special high-voltage automotive cables that withstand high-voltage characteristics, and the safety level is higher than that of low-voltage wires. The structure of high-voltage cable is mainly composed of conductor and sheath. The conductor is made of wound tinned annealed copper, and the insulator adopts 120--200 degrees Celsius level, heat-resistant, halogen-free XLPE. The sheath adopts heat-resistant 105--180 degrees Celsius, Pb-free PVC (or HF-XLPO, TPE-E, PP-FR, ETFE: optional). The wire color identification of high-voltage cables adopts color identification, and the grounding wire or wire core for similar protection purposes in the cable must adopt yellow-green identification marks. The wire color identification of the cable core of the multi-core cable adopts the wire color identification method of the low-voltage wire. 3. High-voltage wire harness wrapping and fixing method The high-voltage wire harness wrapping and fixing method is an important part of the high-voltage wire harness design. The high-voltage harness needs to be effectively protected by the orange corrugated tube on its cable jacket, and the two ends of the harness are sealed with orange tape to prevent oil and water from pouring in and affecting the waterproof performance of the equipment interface. The high-voltage harness cannot be located at the lowest position or the outermost side of the chassis, which may cause the high-voltage harness to wear and cause a high-voltage short circuit. The common method is: a high-voltage harness protection plate is installed on the chassis. The high-voltage harness is generally fixed to the body bolts with special mesh ties. Summary The high-voltage harness design is a key part of the electrical system of electric vehicles, which is related to the overall safety of the vehicle and the person. Line protection design, high-voltage cable selection, and high-voltage harness wrapping and fixing methods are the three main aspects of high-voltage harness design. Line protection design is an important part of high-voltage harness design, and its main purpose is to prevent circuit overload and short-circuit failures. High-voltage cables are selected from special high-voltage automotive cables that need to withstand high-voltage characteristics, and the safety level is higher than that of low-voltage wires. The high-voltage harness wrapping and fixing method needs to be effectively protected by the orange corrugated tube on its cable jacket, and the two ends of the harness are sealed with orange tape to prevent oil and water from pouring in and affecting the waterproof performance of the equipment interface. Through the introduction of this article, we can understand the importance and complexity of high-voltage harness design. High-voltage harness design needs to consider many factors, including line protection design, high-voltage cable selection, and high-voltage harness wrapping and fixing methods. Only through scientific design and strict testing can the safety and reliability of high-voltage harnesses be ensured.

Recommendations In the design of high-voltage harnesses, the following measures are recommended: Use high-voltage fuses as a protection measure to prevent circuit overload and short-circuit faults. Select special high-voltage automotive cables that withstand high-voltage characteristics, which have a higher safety level than low-voltage wires. Use orange corrugated tubes and orange tape to wrap and fix high-voltage harnesses to prevent oil and water from pouring in and affecting the waterproof performance of the equipment interface. Strictly test the safety and reliability of high-voltage harnesses to ensure that they meet national standards and industry requirements. By taking these measures, the safety and reliability of high-voltage wiring harnesses can be ensured, providing protection for the safe operation of electric vehicles.