Basic concept of new energy wiring harness

With the continuous improvement of modernization and the strengthening of environmental awareness, new energy vehicles have gradually become an important direction for people to choose. The electric system used in new energy vehicles not only needs efficient and stable battery power supply, but also needs complex and precise electrical wiring system to ensure the stable transmission and control of electric energy. New energy wiring harness as an important part of the new energy vehicles, its quality and stability has a vital impact on the working effect, safety performance and life of the entire electrical system.Electronic wiring harness

First, the basic concept of new energy wiring harness

New energy wiring harness is a cable bundle used for the electrical circuit of new energy vehicles, which is a power transmission component composed of insulated cables, connectors, protection tubes, terminals and so on. The new energy wiring harness is responsible for realizing the electrical signal transmission between the new energy vehicle battery, motor and controller, including various types of lines such as power lines, ground lines, signal lines, etc.; it also needs to identify and strip different lines to prevent abnormalities such as short circuits, contact problems and wear or damage of foreign objects.Automobile wiring harness

New energy wiring harnesses are more complex in structure compared to traditional vehicle harnesses, because the number of electronic components in new energy vehicles is higher, and also due to the working voltage and current and other factors are higher, so the wiring harnesses are required to have high voltage resistance, high temperature resistance, low impedance in addition to the basic characteristics, there are extremely high quality requirements. At the same time, the New Energy Harness also requires a fine calculation of electrical losses to ensure that the harness can efficiently and stably complete the power transfer and control.Aviation wiring harness

Second, the new energy harness building blocks

The new energy harness is usually composed of the following modules:

1, cable: is the core of the new energy harness, is also the main carrier of the power signal. New energy vehicles are responsible for the transmission of many types of power signals, so there are many types of cables, mainly rated voltage levels, cross-sectional area and other different specifications of the cable, coaxial cable, flat cable, extruded cable and other cable types.

2, connector: connector is mainly used to wind the cable into the interface of a component, the type and number of its different models and differences. In new energy vehicles, the connector is generally used inside the metal spring crimp cable to ensure that the cable connection is tight and will not loosen. At the same time, the connector shell also needs to have multiple protection functions such as waterproof, dustproof and temperature resistance.

3, protection tube: mainly used for the protection and bearing of new energy harness, its many types, including soft and hard plastic protection tube, corrugated tube, casing, insulation tube, etc.. The protection tube mainly carries the cable in the vehicle use may encounter external impact, rain soaking, sunlight and other effects on the line, but also need to be extracted and stretched in the process of multiple times to prevent the cable from breaking and breaking.

4, terminals: new energy vehicles, terminals are mainly used to connect the signal transmission between the cable and equipment parts, but also used for cable and battery, motor, controller and other terminal equipment parts between the fixed.

Third, the technical requirements of the new energy wiring harness

The core technology of the new energy harness lies in high quality, high stability and intelligent control, which includes the following aspects:

1, material requirements: harness materials must have high temperature resistance, low smoke halogen-free, waterproof and non-toxic properties, and meet environmental standards.

2, structural requirements: the structure of the new energy harness should be as fine as possible, and in the bus route design shall consider the equipment to minimize the length of the cable.

3, line design requirements: the line design of the new energy harness should avoid process suspension, as close as possible to the body. At the same time, in the design process, need to combine the actual working conditions, vehicle selection and electrical system planning and other comprehensive factors, from the number of harnesses, cable types, cable length and connector types and other aspects of reasonable matching.

4, performance testing requirements: new energy wiring harness performance testing should be evaluated through a variety of classical experimental methods such as voltage, current, power and impedance to ensure the stability and reliability of the new energy wiring harness.

5.Processing requirements: In the manufacturing process of new energy wiring harness requires multiple processing, stripping, stranding, winding and other processes, requiring each processing process in strict accordance with the process specifications to ensure the quality of each link.

Fourth, the application of new energy harnesses

At present, the application of new energy wiring harnesses in the market has been relatively rich in new energy models, which are mainly used in the following areas:

1, motor control: motor control field is a key application direction in the new energy harness, the new energy vehicle motor control and permanent magnet synchronous motor control needs to be monitored on site first, in order to ensure the stable operation of the motor.

2.Battery management: The management of the battery is an important part of the new energy vehicles. New energy wiring harness is used in the field of battery management, mainly for battery measurement system and battery output signal transmission.

3.Environmental monitoring: The environmental monitoring of new energy vehicles mainly refers to the collection and transmission of information such as vehicle temperature, humidity and fuel temperature. New energy wiring harnesses have great application prospects in this field.

Conclusion:

The importance of the new energy wiring harness is no less than any other component, and its quality, stability and intelligent control will directly affect the efficiency, performance and life of new energy vehicles and many other factors. With the continuous expansion of the new energy vehicle market, the use of new energy wiring harnesses will be more and more models, which brings great development opportunities and challenges for new energy wiring harness manufacturers, must continue to strengthen the research and development and production of new energy wiring harnesses to ensure that the electrical system of new energy vehicles in a stable, reliable, environmentally friendly and efficient at the same time, but also must be more intelligent.

​Basic concept of new energy wiring harness

Basic concept of new energy wiring harness