Technical specification for high voltage harness of electric vehicle

This specification specifies the symbols, codes, terms and their definitions, design criteria, layout requirements, structural design requirements, material selection requirements, performance design requirements, design calculation methods, safe use requirements, etc. involved in the design process of high-voltage wire harness for electric vehicles.

The main function of the high-voltage harness is to safely transfer current under voltage and the required installation environment; Safety rules for high-voltage electricity must be observed.

Terms and definitions

1. Working voltage: the maximum AC voltage (RMS) or DC voltage (regardless of instantaneous voltage) that may be generated by the electrical system under any normal working condition.

2. High voltage: according to the specific voltage level, the voltage level of electric vehicles is level B.

DC: dc60v

AC: (15hz-150hz) ac25v

3. High voltage system: all systems directly or indirectly connected to high voltage circuits, including harnesses (cables and plug-ins) and equipment (loads, generators, energy storage systems), are called high voltage systems.

4. Live parts: conductors or conductor parts that are energized during normal use.

5. Direct contact: contact between personnel and live parts

6. Exposed conductive parts

According to GB 4208, the conductive parts that can be reached by ipxxb test finger.

Note 1: this concept is for specific circuits. The live parts in one circuit may be exposed conductors in another circuit. For example, the body of an electric vehicle may be the live parts in the circuits of light and wiper motor, but for the power circuit, it is exposed conductors.

7. Indirect contact: contact between personnel and exposed conductive parts that become live in case of basic insulation failure.

8. Creepage distance: the shortest distance along the surface of insulating material between the live part of the connecting terminal (including any conductive connector) and the electrical chassis, or between two live parts with different potentials.

9. Conductive part: a part that can pass current. It is not conductive under normal working conditions, but may become a live part in case of basic insulation failure.

10. Crimping: the contact terminals and wires are generally crimped, and the optional ones, such as hard welding or soft welding, can be reasonably selected by checking the environment and needs. For simplicity, the connection in this design specification specifically refers to crimping.