Overview of EV high-voltage harness process

China [CN]

Nowadays, the manufacturing process of high-voltage wire harness is a part of new technology, which is determined by high level manual operation and up to 85% of manufacturing added value. The rationalization potential of manufacturing automation has not been fully utilized. Nevertheless, automation is a key driver for meeting all the requirements of manufacturing transformation.

The protagonists of new energy vehicles are high-voltage connectors and high-voltage wire rods. High voltage connector for new energy vehicles is a mechatronics product, which consists of four parts: contact, insulator, housing and accessories. The contact is the core part of the connector, which completes the connection of optical signal and electrical signal. The vehicle needs to complete the connection of vehicle optical signal and electrical signal through contact insertion. Insulators and housings are mainly used for fixed insulation and mechanical protection.

The manufacturing process integrates electrical performance design, numerical control processing, stamping technology, plastic stamping technology, precision die casting technology, strict testing means and other technologies. 

The quality and accuracy of high-voltage connector products directly affect the electrical, mechanical and environmental performance of the connector, thereby affecting the safety of electric vehicles. Therefore, the quality requirements and manufacturing accuracy of high-voltage connectors are relatively high, which belongs to the connector field of high-end products with high added value.

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