High voltage wiring harness technical requirements for electric vehicles

1. Dimensions, specifications, test methods and requirements for copper conductor cables and QC/T 1037-2016 high voltage cables for road vehicles.

2. Power line with plug-in adopts orange (RAL2010) insulation line specification;

3. Power cable requirements:

1) Conductor: stranded copper conductor (copper wire with diameter of 0.15mm);

2) Resistance voltage: 3000V (AC/50Hz) voltage platform for 5min, no flashover or breakdown; Tear strength > 8MPa;

3) Operating temperature: (−40℃ ~ +150℃);

4) Minimum bending radius requirements: cable laying: 4 x cable diameter;

5) Sheath: wear-resistant silicone rubber; The insulation layer is silicone rubber, which conforms to ISO 6722; Insulation detection requirements: Insulation resistance ≥500MΩ, without shielding cable core insulation and outer sheath; Detection of shielded cables :a. Insulation between core and outer sheath; b. Insulation of wire core and shielding layer; Flame retardant in line with IEC60332-1, oil resistance in line with ISO 6722;

4. The high voltage cable shall be covered by bellows. For specific requirements, see Technical requirements 5, 6, 7;

5. bellows orange (RAL2010), temperature range: (-40℃ ~ 125℃), flame retardant grade V-0;

6. All bellows are closed bellows (open bellows can be used if the length is less than 300mm); The difference between the inner diameter of the bellows and the outer diameter of the cable is less than 5mm; Both ends of the open corrugated pipe and the middle are wrapped with PVC tape; Bellows inner diameter D requirements: line length ≤1.5m, D≤22mm; Line length > 1.5m, D≤25mm;

7. The voltage resistance between the inner and outer rubber covers of copper terminals and the outer rubber covers of cables is 2000V AC; Contact resistance on the terminal ≤3mΩ, terminal plug times > 500;

8. If the cable is shielded, perform the following operations:

1) There is no need to draw out the cable shielding layer: after the cable shielding layer is stripped, keep 10mm, fold the insulation tape backward and wrap it for 2-3 turns, bind and fix it, expose the braided wire without shielding, and plastic seal the heat shrink sleeve;

2) Separate shielding layer wire should be drawn out: the ground wire should be black soft copper wire ≥1.0mm², and the crimping position should be sealed with thermoplastic sleeve;

9. The wiring harness shall be free from scratches, displacement, detachment, dislocation and bending of the wiring harness. There shall be no broken wire or loose-wire phenomenon in all the crimping parts.

10. All materials meet the environmental requirements of "ROHS";

11. The unit in the drawing of power wire harness is unified: mm (mm), and the tolerance requirements are as follows:

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