Electric vehicle high voltage wiring harness and production process

Electric vehicle high-voltage wiring harnesses connect various components of the high-voltage system. As a high-voltage transmission medium, it is the main carrier of the power output of electric vehicles. It is mainly used to transmit electric energy and shield external signal interference.

Automotive high-voltage wiring harness has the characteristics of high voltage resistance, high current, high protection level, and anti-electromagnetic interference. It is the neural network of the high-voltage system of pure electric vehicles, and it is a key component that affects the performance and safety of the whole vehicle. Pure electric vehicle high-voltage wiring harnesses are generally divided into power battery high-voltage wiring harnesses, motor controller high-voltage wiring harnesses, fast charging socket wiring harnesses, slow charging socket wiring harnesses, air conditioning system wiring harnesses, and charging high-voltage wiring harnesses. Wire harness between charger, A/C compressor and traction battery pack heater.

The high-voltage wiring harness is mainly composed of high-voltage connectors, high-voltage cables, covering layers (tape, heat shrinkable tubes, corrugated tubes, wear-resistant self-rolling tubes, etc.), protective plates, etc. The process of producing high-voltage wire harness mainly includes wire cutting, accessory pre-installation, terminal crimping/ultrasonic welding, shielding crimping, wire harness assembly and electrical testing.

Due to the characteristics of high voltage, high current, and large number of large-diameter wires, the high-voltage wiring harness of pure electric vehicles faces challenges such as wiring, safety, shielding, weight and cost. As a high-value pure electric vehicle component, high-voltage wiring harness can contribute to the cost reduction of the whole vehicle through continuous cost optimization through research. The cost reduction work is a continuous optimization and continuous activity, and the follow-up needs to be continuously optimized, so as to minimize the cost of the whole vehicle and provide customers with more competitive products.