High-voltage Wiring Harness is usually used in battery packs, high-voltage distribution boxes, drive motors, charging ports and other circuits.Compared with low-voltage Wiring Harness, it emphasizes electrical safety, shielding, anti-interference and environmental durability. It is recommended to focus on the following aspects when selecting.
1) Conductors and insulating materials
Common conductors are copper or tinned copper, with multiple fine strands to improve flexibility; insulation materials must meet temperature resistance, voltage resistance, chemical resistance and flame retardant requirements.Different platforms have different requirements for temperature levels and voltage levels, and must be selected according to project specifications.
2) Shielding structure and grounding method
In order to suppress EMI, braided shielding/aluminum foil + braided composite shielding is common.The shielding layer termination method (360° crimping, shrapnel, shielding shell) will directly affect the shielding effect and reliability.
3) High voltage connector and interlock (HVIL)
High-voltage connectors usually integrate structures such as secondary locks, CPA, and terminal anti-retraction; HVIL is used to detect the connection status of high-voltage circuits, and the Wiring Harness end needs to ensure the interlocking terminal crimping, insertion, and stable circuit continuity.
4) Creepage/clearance and wiring paths
During installation, avoid high-temperature heat sources and sharp edges, and reserve a reasonable bending radius; it is recommended to add sheaths or bellows at perforations and corners, and fix key positions to avoid long-term vibration and wear.
5) Validation test recommendations
Common verifications include: continuity/short circuit, insulation resistance, withstand voltage, shielding continuity, insertion and extraction force and locking force, salt spray/temperature and humidity cycle/vibration, etc.It is recommended to maintain first article verification and key process inspections during the mass production process.
Conclusion
The risks of high-voltage Wiring Harness often come from "material mismatch" and "out of control assembly details".Only by forming a closed-loop verification in the four stages of design, procurement, processing and loading can safety hazards be eliminated in advance.
Statement: This article is a technical popularization and selection suggestion. The specific standards and test conditions are subject to the project specifications.