Development of High Voltage Wiring Harness -- Balance between Safety and Lightweight

As the blood vessel and nervous system of new energy vehicles, high-voltage wire harness has an impact on new energy vehicles. The safety of high-voltage wire harnesses is the basic guarantee for the safety of new energy vehicles. Their technical development plays an important role in improving the performance of new energy vehicles.

Safety is the most important indicator of the high-voltage harness.

The safety design of a high-voltage harness is mainly embodied in insulation, withstand voltage protection, overload, connector IP grade, equipotential balance, high-voltage harness routing, etc. From the perspective of safety, the use of materials with better conductivity and thermal conductivity is conducive to optimizing the energy efficiency of high-voltage wire harnesses and reducing the working temperature rise. The use of materials with better tensile strength and plasticity is conducive to improving the reliability of high-voltage wire harnesses in the face of vibration and friction during production, assembly, and vehicle operation, and is conducive to optimizing the spatial layout of the wire harness. Materials with more stable chemical properties can prevent corrosion, ensure good contact between high-voltage harness terminals and connectors, and reduce safety risks caused by poor contact.

Lightweight is a common concern of both new energy vehicles and traditional vehicles. High-voltage wire harness is an important field of lightweight new energy vehicles.

Lightweight is helpful to improve energy efficiency, increase the range of new energy vehicles, and reduce costs appropriately. However, when considering the lightweight scheme, it is necessary to ensure the system's safety. Comprehensively consider the whole system's risk and life cycle cost.

First, any lightweight scheme cannot increase the security risk at the cost of being lightweight within the security range. Secondly, lightweight design should not only consider local optimization, but also the lightweight and cost of the whole vehicle system. For example, for the lightening of high-voltage harness materials, in addition to the changes to the harness itself. It is also necessary to consider the impact on terminals and connectors. The change of electromagnetic shielding, and the impact on system maintenance and repair in the cycle of the whole vehicle.