The high-voltage wiring harness for new energy vehicles refers to the wiring harness that connects the battery and the motor, transmitting electrical power and control signals. It plays a crucial role in the power transmission system of electric vehicles. Unlike traditional cars, new energy vehicles typically operate at voltages above 400V, significantly higher than the 12V systems in conventional vehicles. This necessitates greater safety and reliability in their wiring systems.

Key Features of High-Voltage Wiring Harnesses for New Energy Vehicles:

1. High Voltage: New energy vehicle cable in electric vehicles typically need to withstand voltages above 400V. This requires excellent insulation properties and high electrical safety standards.

2. High Temperature Resistance: The motors and batteries of new energy vehicles operate in high-temperature environments, demanding wiring harnesses that offer superior heat resistance and thermal conductivity.

3. Durability: EV high voltage cable must endure constant bending, stretching, and friction over extended periods. Therefore, they require robust materials and well-designed structures to ensure longevity and performance.

4. Corrosion Resistance: Since new energy vehicles often operate in humid environments, high-voltage wiring harnesses must have corrosion-resistant properties. The materials and manufacturing processes are rigorously tested to ensure their resistance to wear, heat, and corrosion, complying with various safety standards and regulations.

Overall Requirements for High-Voltage Wiring Harnesses:

a. The performance and reliability of high-voltage wiring harnesses must meet the overall vehicle requirements.
b. The wiring harnesses must adhere to high-voltage cable technical specifications.
c. The electromagnetic compatibility (EMC) of the high-voltage harnesses should comply with the limits for electromagnetic radiation intensity specified in GB/T 18387.
d. Mechanical shock and vibration resistance must meet the relevant standards in GB743-2006.

Technical Requirements for High-Voltage Connectors:

a. Initial selection of connectors is based on vehicle operating voltage and the power of controlled components.
b. Operating temperature: -40°C to 125°C.
c. Withstand voltage test: AC 2500V/1min, 50Hz.
d. Insulation resistance: ≥500MΩ under normal conditions, ≥5MΩ in humid conditions.
e. Contact resistance: ≤0.2mΩ.
f. Plug/unplug cycles: ≥500 times.
g. Protection level: IP68 & IP6K9K.
h. Corrosion resistance: 48 hours of salt spray or more, with 100% conductivity after testing.