Overview: This paper introduces the process of heavy-duty new energy high-voltage wire harness decomposition, and briefly analyzes the selection of raw materials, the treatment of the shielding layer, and the influence of the wire on the waterproof performance of the connector. 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 wire harnesses 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 wire harnesses directly affects the transmission effect of power or signals and even the stability of the high-voltage system of the whole vehicle. Therefore, it is increasingly valued by high-voltage wire harness manufacturers and parts suppliers. Whether it is 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 car 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 production process mainly considers the following four aspects in the preparation: ① Raw material selection; ② Shielding layer treatment; ③ Quality control; ④ Product application issues. This article analyzes the processing technology based on the above four aspects and proposes solutions.
Shielding layer processing: In order to reduce the impact of external electromagnetic fields on power or communication lines, high-voltage cables often need to ground the shielding layer. Shielding grounding is usually handled in two ways: single-end grounding of the shielding layer and double-end grounding of the shielding layer. Single-end grounding is suitable for shorter lines, while power cables are grounded on both sides; most high-voltage connectors require the shell and shielding layer to overlap, U/V/W three cables need to contact the shield, and there is also a lead wire shield.
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