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February 02, 2024

Routing requirements for high-voltage wiring harnesses in electric vehicles

      Electric vehicle power batteries to high-voltage distributors, motor controllers to motors, AC and DC charging and other high-voltage components are all connected through high-voltage wire harnesses. The internal wiring of electric vehicles is complex, and the layout of high-voltage wire harnesses inevitably needs to pass through sharp edges or vias. At this time, in order to protect the safety of the wire harness, it is necessary to design a protection for the high-voltage wire harness. When developing the whole vehicle, the high-voltage wire harness should be kept away from heat sources and vibration locations as much as possible. High-voltage wire harnesses carry large currents and voltages, and have large wire diameters and weights. In order to avoid stress concentration in the same place, the minimum bending radius of the high-voltage cable is generally greater than 5 times the wire diameter.
     The wiring of the high-voltage harness of the drive motor should take into account the influence of component movement and vibration. The size of the high-voltage harness should be reasonably designed to meet the stress of the length distribution and avoid the accumulation of the harness due to excessive length. In order to avoid the harness being damaged by scratches on other components, the harness should add a rubber ring buffer and a fixed structure design of the guide groove.
 
   There is EMC electromagnetic interference inside the car. In order to reduce and avoid the influence of electromagnetic interference on high-voltage components, the high-voltage harness adopts a shielding structure to avoid high-frequency noise emission. It is worth noting that in order to avoid interference caused by cross-overlapping of high-voltage harnesses, high and low voltage harnesses must be routed and laid out separately.
 
   High voltage has long exceeded the safety voltage of the human body. The car body adopts the same grounding method as the low-voltage system. In order to use it safely and reliably, the high-voltage harness must adopt a double-track system.
 
   High-voltage connectors are an important part of high-voltage harnesses. When selecting, the rated working voltage, current, insulation resistance, withstand voltage level, shielding and interlocking and other related electrical performance parameters need to be considered. Electric vehicles often use built-in high-voltage interlocking because their layout is more compact and smaller. High voltage connectors usually need to be tested for vibration resistance and corresponding mechanical life, which is also one of the ways to detect whether the mechanical performance is good.

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