How is the High Voltage Wiring Harness Made?
September 30,2022
When the high-voltage wiring harness is operated, it is strictly forbidden to plug and unplug the high-voltage system connector or cause the expansion of the accident.
High-voltage wiring harness process analysis
- Cutting and peeling
Cable roundness (determines the complexity of shield handling)
The end face is flush, and the scratched wire meets the standard. After peeling, no loose wire or bulge is allowed.
- Stripping of multi-core cables
Multi-core cables also need to be stripped individually for each cable. Before stripping, the filler needs to be cut off, and the scratched wires must meet the standards.
When assembling multi-core cables, avoid cross-cable cables. The stress on a single cable may easily cause the terminals to come out.
- Pre-installed tail accessories
According to the structure of each connector, the content of the pre-installed tail accessories is defined.
Choose to use open or closed bellows according to the actual situation. If you choose closed bellows, the length of the bellows determines whether it is convenient to install the tail accessories.
- Shielding layer treatment and peeling
Wear goggles to prevent the shielding wire from splashing.
How to deal with shielding and breaking up/out turning needs to focus on process control.
The shielding layer treatment is strictly prohibited from leaking wires, piercing the wire skin, and other undesirable phenomena.
- Closed terminal crimping
Finger coverings are required (to prevent contamination by perspiration, and silver-plated terminals need to be protected from light when stored).
Comply with the requirements of high voltage wire harness closed terminal crimping.
Design the corresponding crimping positioning tool according to the connector structure.
Customized crimping dies, one-time crimping (four-point crimping, MW crimping, hexagonal plus-point crimping dies).
After crimping, the section state, pull-off force, and temperature rise are analyzed to determine the height and width dimensions.
- Shield ring crimping
There are size requirements between the terminal and the shielding ring, and a special positioning tool needs to be made.
Customized crimping die, one-time crimping (hexagonal crimping, hexagonal plus point crimping die).
After the crimping is completed, excessive deformation of the tail protrusion is not allowed. Excessive deformation affects the assembly of the shielding ring. The minimum size of deformation is analyzed according to each connector structure.
- Connector assembly
When the low-voltage line and the high-voltage line are wound and assembled, a certain length is reserved at the tail of the low-voltage wire harness to prevent it from being pulled out by force.
Some terminals need to be designed with special tooling to prevent the deformation of the wire bulge when installing the connector.
The waterproof bolt assembly does not allow sharp objects to be pierced, and special tooling needs to be designed.
- Detection
Electrical properties: continuity, insulation withstand voltage, in which the high voltage detection time is tested according to 1 minute between each point during the test, but in actual production, it depends on the production situation (usually 2s-10s, not less than 2s).
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