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New energyElectric wire harnessFunctionally, it can be divided into two types: the power line carrying electric drive actuators (actuators) and the signal line transmitting sensor input commands. Power lines are thick wires that carry large current, while signal lines are thin wires that do not carry electricity (optical fiber communication); For example, the cross sectional area of the wire used for the signal circuit is 0.3 and 0.5mm2.

The cross-sectional area of the wires used for the motor and actuator of the electric vehicle harness is 0.85 and 1.25 mm2 respectively, while the cross-sectional area of the wires used in the power circuit is 2, 3 and 5 mm2 respectively; Special circuits (starter, alternator, engine ground wire, etc.) have different specifications of 8, 10, 15 and 20mm2. The larger the cross-sectional area of the wire, the greater the current capacity. The selection of wires is not only limited by the electrical performance, but also by the physical performance of the vehicle, so its selection range is wide. For example, the door of a taxi that is frequently opened/closed and the wire passing through the car body should be composed of wires with good flexibility. Conductors used in high temperature areas generally use vinyl chloride and polyethylene coated conductors with good insulation and heat resistance. In recent years, the number of electromagnetic shielding wires used for weak signal circuits has also increased.

With the increasing function of electric vehicle harness and the wide application of electronic control technology, there are more and more electrical parts and wires. The number of circuits and power consumption on electric vehicles have increased significantly, and the harness has become thicker and heavier. This is a big problem that needs to be solved. How to arrange a large number of harnesses more effectively and reasonably in a limited space so that the harnesses of new energy electric vehicles can play a greater role has become a problem facing the automobile manufacturing industry.

What are the characteristics of high-voltage harness of new energy electric vehicles?

The high voltage harness of new energy electric vehicles has much higher performance in terms of voltage and temperature resistance than the low voltage harness. Domestic main engine manufacturers usually use shielded high voltage wire.

Shielded high-voltage wire can reduce the impact of EMI (electromagnetic interference) and RFI (radio interference) on the whole vehicle system. The whole circuit of the high-voltage harness is shielded and connected. The shielding layer of the high-voltage harness at the interface of the motor, controller and battery is connected to the battery motor controller shell through the plug-in and other crimping structures, and then grounded with the body. Shielding of high-voltage lines is not necessary for conducting data of cables, but it can reduce or avoid the radiation of high-voltage lines. (Necessity of shielding high-voltage wire harness) Withstand voltage performance: the high-voltage withstand rating of conventional electric vehicles is 600V, and the voltage of commercial vehicles and passenger cars can be as high as 1000V;

Current resistance: according to the current of high-voltage system components, it can reach 250~400A;

Temperature resistance: high temperature resistance is divided into 125 ℃, 150 ℃ and 200 ℃, and 150 ℃ conductor is commonly used for high temperature resistance; The normal low temperature is - 40 ℃.