High voltage wiring harness layout design all points

Before the space layout of the high-voltage wiring harness, the position of the equipment end on the vehicle is usually determined. At this time, the high-voltage wiring harness layout needs to be rationally routed based on the vehicle 3D data, and attention should be paid to the protection, fixing and concealment of the high-voltage wiring harness during the process. We mainly introduce the main points of high voltage wiring harness layout.

In general, the layout of high-voltage equipment and the layout of wiring harnesses are also related and need to be considered each other. The determination of the layout plan is not locked unilaterally.

1, HV harness space layout basic principles:

The HV wiring harness should be avoided from the passenger compartment as far as possible. If the HV wiring harness needs to be connected to the front compartment and trunk due to design requirements, the HV wiring harness can be routed under the vehicle chassis through the body sheet metal hole, which can also facilitate the EMC design of the HV wiring harness.

l Avoid cabling with the low-voltage harness to prevent interference with the low-voltage harness;

l High and low voltage wiring harnesses should avoid crossing cables as far as possible. Parallel wiring of high and low voltage wiring harnesses should be 100mm apart (unless EMC is not affected).

l At least 100mm between the high pressure harness and the fuel line;

l The distance between the associated positive and negative wires shall be maintained at 20mm (measured by the distance from the outer edge of the shielding layer)

l The length difference of the associated wires shall not exceed 35mm;

l The gap between the high voltage wiring harness and the stationary parts is at least 10mm.

l The clearance between the high-voltage wiring harness and the moving parts is at least 25mm;

l Avoid the area where the body is deformed after a collision. This prevents the high voltage of the body from being cut by sheet metal or the insulation layer being damaged after an accidental collision. For example, do not route cables inside the front and rear anti-collision beams, side sheet metal, and door.

2, the associated high-voltage wiring harness (such as the motor three-phase line or the main power battery pack line) must be unified and symmetrical arrangement.

3. The wiring harness should be protected and fixed in the process of space layout.

4. The bending radius of the wiring harness should not be too small, too small should cause the failure of the connector seal and damage to the wire insulation. The appropriate bending radius of the wire is shown in the following table.

Note: Outer diameter refers to the diameter of the outermost insulating skin; Some manufacturers of high voltage large square wire bending radius can be less than the above table requirements, need to determine the bending radius and test requirements and methods with the supplier.

5. When the wiring harness passes through the body sheet metal holes, use rubber holes to protect and seal the wiring harness, and secure the wiring harness before and after the passing holes.

6, Connector Layout

During the process, the operable space of the connector needs to be considered. In general, simulation can be carried out in 3D software such as CATIA during the layout process to determine whether it is operable.

Avoid parts that have water splashing or are vulnerable to stone strikes. If it is necessary to install in such locations for relevant reasons, use metal protection plates.

Operation space It is necessary to consider the distance generated during the rotation or translation of some components during the disassembly and assembly of the connector. The following is the space size of the HV2000 connector.

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