What is the wire harness of new energy vehicles?
2022-09-14
What is the wire harness of new energy vehicles
The power supply and various electrical parts on the new energy vehicle are physically connected through the harness, which is distributed throughout the vehicle. If the power system is compared to the heart of a car, then the harness is the neural network system of the car, which is responsible for the information transmission between the various electrical parts of the car. With the continuous improvement of people's requirements for comfort, economy and safety, the types of electronic products on automobiles are also increasing, and the failure rate of more and more complicated automobile wire harnesses is also increasing accordingly.
Features of new energy vehicle harness:
1. High voltage 2. High current 3. Sealing 4. Heat resistance 5. EMC performance, 6. Durability 7. Safety 8. High voltage connector characteristics 9. High voltage wire characteristics 10. Charging port characteristics
The low-voltage harness of new energy vehicles is not very different from that of traditional vehicles. The disappearance of the engine has reduced the engine harness. The main difference lies in the emergence of high-voltage harness, power battery, the application of electric motor drive, and the electronic application of other parts such as on-board charger and compressor, which has brought a new harness system on the 600V high-voltage architecture.
There are some differences between new energy vehicle high-voltage lines and ordinary vehicle cables, mainly due to the great changes in the use environment
1. High voltage and high current (on-board)
It can reach 600/300A, but the battery voltage of traditional fuel vehicles is usually 12V, and the withstand voltage level of corresponding wires is less than 60V.
2. Large wire diameter, large number of cables (on-board)
High voltage battery frequency transformer/low voltage battery/air conditioning compressor/electric heating/power distribution sheet. Many electrical structures are connected by cables. Huge cables are configured in limited space.
3. Exposed space (outside the vehicle)
The cables of the charging gun are exposed for a long time, and there are strict requirements for weather resistance, abrasion resistance, bending resistance, tear resistance, etc.
The kinds of auto wiring harness as below :
As the high-voltage harness in the vehicle is characterized by large voltage/current and large number of wires with large wire diameter, the harness design is faced with wiring, safety, shielding, weight and cost.
According to the cooperative customer cases of Rieter Electric, there are several sub categories of automobile harnesses as follows:
Electric vehicle charging plug-in cable
Engine harness of hydrogen energy vehicle
Fuel cell system harness of hydrogen energy vehicle
Car parking air conditioner harness
Fire truck aerial ladder cable
Wire harness for electric vehicle battery system
Cable assembly for racing display
Cable assembly of car reverse parking sensor
Vehicle anti-collision cable assembly
Automobile motor cable device
Automobile brake clutch harness
Automobile steering system harness
Harness for public emergency vehicle alarm system (such as police car, ambulance, etc.)
Automotive wires can be divided into:
Battery wires, high-voltage conductors (for new energy vehicles, with a withstand voltage level of DC greater than 60V and less than 600V), coaxial cables, low-voltage conductors (with a withstand voltage level of DC less than 60V or AC less than 25V), etc.
The power supply and various electrical parts on the new energy vehicle are physically connected through the harness, which is distributed throughout the vehicle. If the power system is compared to the heart of a car, then the harness is the neural network system of the car, which is responsible for the information transmission between the various electrical parts of the car. With the continuous improvement of people's requirements for comfort, economy and safety, the types of electronic products on automobiles are also increasing, and the failure rate of more and more complicated automobile wire harnesses is also increasing accordingly.
Features of new energy vehicle harness:
1. High voltage 2. High current 3. Sealing 4. Heat resistance 5. EMC performance, 6. Durability 7. Safety 8. High voltage connector characteristics 9. High voltage wire characteristics 10. Charging port characteristics
The low-voltage harness of new energy vehicles is not very different from that of traditional vehicles. The disappearance of the engine has reduced the engine harness. The main difference lies in the emergence of high-voltage harness, power battery, the application of electric motor drive, and the electronic application of other parts such as on-board charger and compressor, which has brought a new harness system on the 600V high-voltage architecture.
There are some differences between new energy vehicle high-voltage lines and ordinary vehicle cables, mainly due to the great changes in the use environment
1. High voltage and high current (on-board)
It can reach 600/300A, but the battery voltage of traditional fuel vehicles is usually 12V, and the withstand voltage level of corresponding wires is less than 60V.
2. Large wire diameter, large number of cables (on-board)
High voltage battery frequency transformer/low voltage battery/air conditioning compressor/electric heating/power distribution sheet. Many electrical structures are connected by cables. Huge cables are configured in limited space.
3. Exposed space (outside the vehicle)
The cables of the charging gun are exposed for a long time, and there are strict requirements for weather resistance, abrasion resistance, bending resistance, tear resistance, etc.
The kinds of auto wiring harness as below :
As the high-voltage harness in the vehicle is characterized by large voltage/current and large number of wires with large wire diameter, the harness design is faced with wiring, safety, shielding, weight and cost.
According to the cooperative customer cases of Rieter Electric, there are several sub categories of automobile harnesses as follows:
Electric vehicle charging plug-in cable
Engine harness of hydrogen energy vehicle
Fuel cell system harness of hydrogen energy vehicle
Car parking air conditioner harness
Fire truck aerial ladder cable
Wire harness for electric vehicle battery system
Cable assembly for racing display
Cable assembly of car reverse parking sensor
Vehicle anti-collision cable assembly
Automobile motor cable device
Automobile brake clutch harness
Automobile steering system harness
Harness for public emergency vehicle alarm system (such as police car, ambulance, etc.)
Automotive wires can be divided into:
Battery wires, high-voltage conductors (for new energy vehicles, with a withstand voltage level of DC greater than 60V and less than 600V), coaxial cables, low-voltage conductors (with a withstand voltage level of DC less than 60V or AC less than 25V), etc.