High-voltage cables for new energy heavy trucks

China [CN]

Product Overview: This article introduces the process of heavy-duty new energy high-voltage wire harnesses, and briefly analyzes the selection of raw materials, the treatment of shielding layers, and the influence of wires on the waterproof performance of connectors. It briefly explains the difficulties of high-voltage wire processing and provides some references for wire harness process designers.

As the link between the three core components of new energy electric vehicles, namely power batteries, drive motors, and high-voltage control systems, high-voltage cables are the medium for high-voltage power transmission and the highway for the transmission and distribution of power and signals of vehicles. The quality of high-voltage cables directly affects the transmission effect of power or signals and even the stability of the high-voltage system of the whole vehicle. Therefore, they are increasingly valued by high-voltage wire harness manufacturers and parts suppliers. Whether used in electric vehicles or heavy trucks, the cable manufacturing and processing process is very important.

Different from low-voltage wire harness systems, high-voltage wire harness systems carry high voltage electricity when used, and the application environment in the vehicle is harsh, and the safety requirements are extremely high. Therefore, in production and processing, the requirements of the processing technology determine the performance of the high-voltage wire harness. The following four aspects are mainly considered in the preparation of the production process: ① raw material selection; ② shielding layer processing; ③ quality control; ④ product application issues. This article analyzes the processing technology based on the above four aspects and proposes solutions.

Raw material selection: The raw materials used in high-voltage wiring harnesses include high-voltage connectors, terminal blocks, high-voltage wires, corrugated tubes, heat shrink tubes, shielding rings, conductive tapes, etc. Among them, the specifications of wires are varied. For example, the same specifications vary greatly due to factors such as voltage, temperature, and bending radius. Therefore, choosing the right raw materials is crucial for product processing.

(1) Wire selection: Commonly used automotive high-voltage wires all use orange wires, and the corresponding specifications and usage conditions, as well as warning signs such as "(Caution High Voltage Danger)" are printed on the outer insulation of the cable. According to the voltage level, it can be divided into AC600V/DC900, AC1000V/DC1500V; the commonly used wire temperature resistance level is 125℃, and different temperature resistance levels such as 150℃, 180℃, 200℃ and other temperature levels can also be selected according to the use conditions; for areas with limited installation space, wires with a smaller bending radius D can be selected, such as silicone wires; according to the use function, it can be divided into shielded and unshielded cables. For different connectors, single-core cables or multi-core cables can be used.

The selection of wires generally follows the following two principles:

First, when the use conditions are clear, select wires according to the most matching outer diameter range of high-voltage connectors. Most high-voltage connectors require waterproof performance ≥IPX7. After the connector and wire are assembled, the waterproof requirements are achieved by squeezing the rubber ring, and the tightening torque is 5-8N·m. Therefore, when the outer diameter of the wire exceeds the adapter range of the connector wire, it will cause processing difficulties or the waterproof effect will not meet the requirements. Taking the Amphenol PL28X-301-70 connector as an example (Figure 1), the optimal wire outer diameter is between 19.2-19.8, and the waterproof effect is best in this range.

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