What is a high-voltage wiring harness for automotive power batteries
The high-voltage wiring harness for automotive power batteries is a wiring harness system used in new energy vehicles to transmit high-voltage electrical energy. It mainly connects the power battery with other high-voltage components (such as motor controllers, fast charging interfaces, etc.) and undertakes the functions of high-voltage current transmission and signal control.
Core function
Youdaoplaceholder0 Power transmission : Connects the power battery with high-voltage components (such as motor controllers, DC/DC converters, etc.) to transmit high-voltage current ranging from hundreds of volts to kilovolts.
Youdaoplaceholder0 Signal control : Some high-voltage wiring harnesses contain shielding layers to reduce the impact of electromagnetic interference on the entire vehicle system.
Youdaoplaceholder0 Safety assurance : It is connected to the vehicle body through the shielding layer to enhance system safety.
Classification and Structure
Youdaoplaceholder0 by function :
Wiring harnesses from power batteries to high-voltage distribution boxes
The wiring harness from the high-voltage distribution box to the motor controller
The wiring harness from the fast charging/slow charging interface to the high-voltage distribution box
Wiring harnesses for connecting high-voltage accessories such as DC/DC and on-board chargers
Youdaoplaceholder0 Technical requirements : It must meet the characteristics of withstand voltage (600VAC/900VDC), withstand temperature (125℃-200℃), withstand current (250A-400A), etc.
The high-voltage wiring harness for automotive power batteries is a key component of the high-voltage system in new energy vehicles. Its main function is to efficiently and safely transmit the electrical energy from the power battery to high-voltage parts such as the motor, charging interface, and DC/DC converter. At the same time, it has multiple safety protection functions.
Electric energy transmission
The high-voltage wiring harness connects the power battery with the motor controller, DC charging port and other components to achieve stable transmission of high current and high voltage, meeting the vehicle's power system and charging requirements.
Safety protection
Youdaoplaceholder0 overcurrent/short-circuit protection : Built-in fuse or relay quickly cuts off the circuit when the current is abnormal, avoiding the risk of fire.
Youdaoplaceholder0 Shielding interference : Shielding design is adopted to reduce the impact of electromagnetic interference on the vehicle system and ensure the stability of signal transmission.
Youdaoplaceholder0 high/low temperature resistance : Utilizing heat-resistant materials (such as XLPE insulation materials), it can adapt to harsh working conditions ranging from -40 ° C to 200 ° C, ensuring long-term reliability.
Machinery and Durability
Youdaoplaceholder0 Anti-wear/anti-corrosion : The outer layer is made of wear-resistant materials and features a sealed design, making it suitable for environments with frequent bending and high humidity.
Youdaoplaceholder0 Wiring optimization : Reduce the impact of vibration and external shock through dedicated path planning.
Faults in high-voltage wiring harnesses of automotive power batteries may involve multiple aspects. The following are common types of faults and corresponding measures:
Fault type and cause
The wiring harness is broken or damaged
High-voltage wiring harnesses may break, short circuit or have their insulation layers damaged during long-term use or accidental collisions, resulting in exposed circuits and posing safety hazards.
Youdaoplaceholder0 Poor contact or oxidation of terminals
Oxidation, loosening or poor fixation of wire harness terminals can lead to increased resistance, local overheating and even cause malfunctions.
Youdaoplaceholder0 insulation layer failure
High temperature, humidity or chemical corrosion may cause the insulation layer to fail, leading to short circuits or leakage.
Youdaoplaceholder0 wire harness vibration wear
Wiring harnesses that are not fixed or do not use metal clips may wear out due to vibration during operation.
Maintenance suggestions
Youdaoplaceholder0 check for external damage
First, check if the wiring harness has any breaks, short circuits or exposed wires. Replace the damaged parts and re-fix them.
Youdaoplaceholder0 check the connectors and terminals
Check all connectors for looseness or oxidation. Clean and re-fix them if necessary.
Youdaoplaceholder0 test insulation performance
Use a multimeter to measure the resistance of the wiring harness to ground (normally it should be greater than 1Ω). If it is less than 1Ω, the wiring harness needs to be replaced.
Youdaoplaceholder0 Safe operation of high-voltage system
When performing maintenance, the high-voltage switch (MSD) must be disconnected, and the battery pack should be left to stand for 15 minutes to release the residual voltage.
Safety Precautions
When conducting maintenance, insulating gloves must be worn to avoid direct contact with high-voltage lines.
When replacing the wiring harness, original factory accessories should be used to avoid false alarms of faults by the BMS due to protocol mismatch.
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