High-voltage harnesses are crucial in new energy vehicles, serving as the main carrier for power output. They transmit electrical energy and shield against interference, directly impacting vehicle performance and safety. This article explores the design and connector selection of high-voltage harnesses, incorporating insights from Dongguan Baori Electronics Co., Ltd., to provide valuable industry references.

Necessity of Design and Connector Selection

Efficient Power Transmission

Reducing power loss during transmission is essential for maximizing battery efficiency and extending vehicle range. High-voltage harnesses must use conductive materials, optimize cross-sectional areas, and minimize resistance and heat loss. They should also handle fluctuating power demands to ensure stable energy supply.

Safety Assurance

High-voltage harnesses require robust insulation to prevent current leakage. Insulation materials must withstand high voltages (typically above 400V) and ensure safety in extreme conditions.

System Reliability

Proper harness routing and fixation reduce vibration and friction, minimizing damage risks. High-quality materials extend harness lifespan and maintain performance in harsh environments.

Cost Optimization

Balancing performance and safety with cost-effectiveness is crucial for market competitiveness. Efficient design and connector selection can achieve this balance.

Design of High-Voltage Harness

Design Scheme

lDesign Goals: Meet high-efficiency and safety requirements using advanced materials and manufacturing processes.

lLayout Design: Plan paths based on vehicle structure, avoid excessive lengths, and use protective measures in vulnerable areas.

lMaterial Selection: Use high-conductivity, heat-resistant, and corrosion-resistant materials like high-purity copper or aluminum. Insulation materials such as XLPE are preferred for their electrical properties.

lManufacturing Process: Employ automated production lines for quality and efficiency, with strict testing protocols.

lSafety Protection: Include overcurrent devices, isolate from other harnesses, and ensure proper grounding.

Materials and Manufacturing Processes

lConductor Materials: High-purity copper or aluminum for conductivity and mechanical strength.

lShielding Materials: Metal braided mesh, aluminum foil, or conductive cloth to prevent EMI.

lSheath Materials: PVC, TPE, or nylon for durability and resistance to environmental factors.

Connector Selection Research

Performance Requirements

lElectrical Performance: Rated voltage above 200V, high insulation resistance, and voltage resistance above 1000V.

lMechanical Performance: Insertion/extraction force within 100N, mechanical life over 5000 cycles, and good vibration resistance.

lTemperature Adaptability: Operate within -40°C to 125°C.

lCorrosion Resistance: Use corrosion-resistant materials like aluminum or zinc alloy with protective coatings.

Dongguan Baori Electronics Co., Ltd.'s Expertise

As a leader in the harness industry, Dongguan Baori Electronics Co., Ltd. leverages advanced equipment and processes to ensure high-quality harnesses and connectors. Our expertise in design and selection supports the development of efficient and safe new energy vehicles.

If you have custom requirements for wire harnesses, welcome to contact Dongguan Baori Electronics Co., Ltd. We have a professional technical team and advanced equipment and will wholeheartedly provide you with high-quality wire harness products and services. We will reply to your inquiries as soon as possible and look forward to cooperating with you hand in hand to create a better future.