The automobile wiring harness is the main body of the automobile circuit and the carrier of the automobile circuit. Automobile wiring harness is the bridge and tie for the work of vehicle electrical components, and the nerve system of the vehicle's power and signal transmission and distribution. The high-voltage wiring harness can be connected to the internal and external wiring harnesses of electric vehicles according to different voltage levels. The main application is the signal distribution of the internal wiring harness of the power distribution box, which can transmit power with high efficiency and high quality, and shield external signal interference. The high-voltage connection system consists of high-voltage wiring harnesses and connectors. Connectors are required for DC/DC, plumbing PTC chargers, air heating PTC, DC charging ports, power motors, high-voltage wiring harnesses, maintenance switches, inverters, power batteries, high-voltage boxes, electric air conditioners, AC charging ports, etc. The high-voltage wiring harness is the neural network of the high-voltage system of the new energy vehicle, which is very important. Therefore, the following points should be paid attention to in the production process:

1.     The connector will reduce the safety characteristics due to the high temperature rise, and even be damaged, so we must consider the temperature range of its work when selecting the connector. 

2.     For wire crimping, there are often most wire harness factories. The quality of the crimping will directly affect the size of its contact resistance. We can’t just judge that the crimping must be reliable only by the pull-off force and other conditions that meet the requirements. We must make detailed terminals. Mirror slicing test to carefully determine the degree of crimping of the terminal.

3.     For the connection of the board end, it is usually connected to the high-voltage box or the inside of the equipment. The connection method is mostly copper row bolt connection. When bolting is used, it is recommended to use loose design bolts to prevent vibration from loosening under working conditions and increase contact resistance. The connection part is loaded, and at the same time, excessive torque must be prevented when the bolt is connected.

4.     The contact of the intermediate plug-in point is mainly realized through the internal contacts. At present, the contacts of each company are different, such as open leaf type, crown spring type, torsion spring type, wire spring type, watchband type, etc., but we Need to consider its plug life, plating, electrical performance stability after plugging and other technical points, as well as the location and occasion of the application to determine which method is appropriate.

5.     For high-voltage systems, the priority of shielding is to consider the rationality of the layout at the system level, followed by the requirements for high-voltage cables and high-voltage connectors. The connectors must have a 360° shielding layer and be effectively connected to the cable shielding layer. , The shielding layer covers the entire connection length to ensure sufficient shielding function and minimize the resistance between the shielding interfaces. During the product life cycle, the shielding connection contact resistance is less than 10mΩ.

KABLE-X Technology（Suzhou）Co., Ltd has been engaged in the production, processing and custom wiring harness for 20 years. Facing the new challenge of the national dual-control policy, we believe that it will also be a new opportunity for KABLE-X Technology（Suzhou）Co., Ltd. We will deploy reasonably and work together to provide customers with high-quality wiring harness.