At present, new energy vehicles have become the main direction of the development of the automobile industry. In order to meet market demand, many traditional auto parts suppliers began to turn to the production of new energy vehicle-related products, such as motors, electronic control systems, etc. As a link connecting various electronic components, wiring harnesses play a crucial role in new energy vehicles. As technology advances, harnesses are being upgraded from traditional copper wires to materials with higher electrical conductivity, such as aluminum alloys or carbon fiber composites. In addition, the development of wireless charging technology also provides the possibility for the realization of fully automated wireless wiring harnesses in the future. As an important part of connecting various electronic components, the wiring harness plays a more prominent role in new energy vehicles.
New energy wiring harness refers to the electrical wiring harness used in new energy vehicles, which is an important part of new energy vehicles. It is mainly composed of wires, cables, connectors, sheathing, etc., used to transmit power and signals, connect various electronic devices and components, in order to achieve the normal operation of new energy vehicles.
Compared with traditional fuel vehicles, new energy vehicles have added key equipment such as batteries and motors, which require corresponding wiring harnesses to be connected. At the same time, with the development of new energy vehicles in the direction of intelligence and networking, the number of electronic devices in the car has also increased greatly, which makes the demand for wiring harnesses rise exponentially.
The new energy harness has the following characteristics:
1.High voltage: The battery voltage of new energy vehicles is high, generally above 300V, so the new energy harness needs to withstand higher voltage.
2. Large current: The motor power of new energy vehicles is large, and it needs to transmit more current, so the new energy harness needs to have a larger conductor cross-sectional area.
3. Anti-interference: The electrical system of new energy vehicles is more complex and vulnerable to electromagnetic interference, so the new energy wiring harness needs to have anti-interference ability.
4. Lightweight: New energy vehicles have high lightweight requirements, so new energy wiring harnesses need to use lightweight materials, such as aluminum wires, thin-wall sheathing, etc.
5. High reliability: the use environment of new energy vehicles is harsh and needs to withstand higher temperature, humidity, vibration, etc., so the new energy harness needs to have higher reliability and durability.
The manufacturing process of new energy wiring harnesses generally includes the following steps:
1. Cutting: According to the design requirements, cut the copper rod or aluminum rod into the required length of wire.
2. Stripped insulation: Strip the outer skin of the wire to expose the conductor.
3. Twisted wire: Twisted multiple wires together to increase the cross-sectional area and strength of the conductor.
4. Insulation: Wrap insulation material on the surface of the conductor to prevent short circuit between the conductors and prevent the conductor from contacting the external environment.
5. Cabling: Twisted multiple insulated wires together to form a cable.
6. Sheath: Wrap sheath material on the surface of the cable to protect the cable from mechanical damage and environmental impact.
7. Marking: Marking model, specification, production date and other information on the cable.
8. Testing: The electrical performance of the cable is tested to ensure that it meets the relevant standards and specifications.
9. Packaging: Pack the cable into rolls or boxes for transportation and storage.
The above is the general manufacturing process of new energy harness, and different types of new energy harness may be different. In the manufacturing process, it is necessary to strictly follow the relevant standards and specifications to ensure that the quality and performance of the new energy harness meet the requirements.
The testing standards of new energy wiring harnesses mainly include the following aspects:
1. Appearance inspection: Check whether the appearance of the new energy wiring harness meets the requirements, such as whether there is damage, deformation, scratches, etc.
2. Size check: Check whether the size of the new energy wire harness meets the design requirements, such as conductor cross-sectional area, conductor diameter, cable length, etc.
3. Electrical performance test: test the electrical performance of new energy wiring harness, such as conductor resistance, insulation resistance, voltage resistance, etc.
4. Mechanical properties test: test the mechanical properties of new energy wiring harnesses, such as tensile strength, bending strength, wear resistance, etc.
5. Environmental adaptability test: test the performance of new energy wiring harnesses under different environmental conditions, such as high temperature, low temperature, humidity, vibration, etc.
6. Flame retardant performance test: test the flame retardant performance of new energy wiring harness to ensure that it will not fuel the fire in the event of a fire.
7. Corrosion resistance test: test the corrosion resistance of new energy wiring harness to ensure that it can be used normally in harsh environments.
8. Reliability test: test the reliability and durability of the new energy harness to ensure that it can work stably for a long time.
The above is the general test standard for new energy harness, and different types of new energy harness may be different. In the testing process, it is necessary to strictly follow the relevant standards and specifications to ensure that the quality and performance of the new energy harness meet the requirements.
New energy harness is an important part of new energy vehicles, and its quality and performance directly affect the safety, reliability and service life of new energy vehicles. Therefore, the design, manufacturing and testing of new energy wiring harnesses need to be carried out in strict accordance with relevant standards and specifications to ensure that their quality and performance meet the requirements. In the next few years, as governments increase their support for energy conservation and emission reduction policies and consumers improve their environmental awareness, new energy vehicle sales will continue to maintain a rapid growth trend. This will drive the related harness demand to further increase. At the same time, intelligence and networking will also become the development trend of new energy vehicles, which will bring more innovative application space for the wiring harness industry.
Post time: Dec-01-2023