Electric vehicle high-voltage wiring harness distribution site and wire diameter design requirements
China [CN] EV high-voltage wiring harness is the internal wiring of electric vehicles, so do you know its specific distribution location? There are five main distribution sites.
1. Power battery high voltage cable, connect the power battery to the high voltage junction box
2. Motor controller cable, connect the cable from the high voltage junction box to the motor controller.
3. Fast charging cable, the cable connecting the fast charging port to the high-voltage junction box
4. Slow charging cable, the cable connecting the slow charging port to the car charger
5. High-voltage accessory wiring harness, connect the high-voltage junction box to the wiring harness between DCDC, vehicle charger, air conditioner compressor, and PTC
High voltage wiring harness design requirements:
1. In the high-voltage system design, the high-voltage circuit must strictly implement the dual-rail system.
2. The circuit of the entire high-voltage wire harness is shielded and connected, and the shielded high-voltage wire can reduce the impact of EMI (electromagnetic interference) and RFI (radio frequency interference) on the vehicle system.The shielding layer of the high-voltage wiring harness of the interfaces of the motor, the controller and the battery is connected to the housing of the motor controller through a crimping structure such as a plug-in, and then connected to the body ground.
3. Withstand voltage performance: 600/900VAC;1000/1500VDC.
4. Current resistance: According to the current of the high-voltage system components, it can reach 250~400A.
5. Temperature resistance: high temperature resistance grades are divided into 125℃, 150℃, 200℃, usually choose 150℃ wire;low temperature conventional -40℃.
6. Generally use thick-walled wire (wall thickness 0.6~1.1mm)
7. Design of wire diameter:
The following factors need to be taken into consideration
① Rated current value of load circuit
② Allowable temperature of wire conductor
③ The ambient temperature around when the wiring harness is working
④ The energization rate decreases due to the temperature rise when the wire itself is energized
⑤ Reduction factor for allowable current of bundled wire harnesses
Verification formula: allowable current value of wire × reduction of energization rate caused by ambient temperature × reduction coefficient caused by bundling > rated current value
EV high-voltage cables are an important part of high-voltage wiring harnesses.OMG is the provider of EV high-voltage cables.For more detailed product information, please visit OMG's official website:https://www.omgevcable.com/
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