7158-3182-20 Connector Waterproof Plug Cavity Seal Waterproof Plugging

The vehicle layout diagram 1 shows the layout of high-voltage components for pure electric vehicles. Reasonably arrange the high-voltage connection harnesses between various high-voltage components such as battery to PDU, motor controller to motor, AC/DC charging, etc. through the layout position of high-voltage components in pure electric vehicles.

If the high-voltage wiring harness needs to pass through sharp edges or through holes, corresponding protective structures or methods should be designed. In the early stage of vehicle development, the wiring harness layout should try to avoid heat and vibration sources as much as possible or maintain sufficient distance from them.

High voltage wire harnesses all have a large outer diameter and weight. To avoid stress concentration, the minimum bending radius of the cable should generally be greater than 5 times the diameter of the wire diameter. To distribute the load reasonably, it is necessary to add support and fixing devices. The spacing between fixed points in the straight arrangement of the wire harness should be ≤ 300mm, and the fixed points in the bending arrangement should be fixed at the two endpoints of the arc. The spacing between the fixed points and the connector should be ≤ 150mm in order to withstand the weight and vibration load of the wire harness. The fixing device must use automotive grade ties and insulation brackets, etc.

The drive motor wiring harness needs to consider the influence of component motion and vibration, and the size of the wiring harness should be reasonably designed to meet the stress distribution of length and avoid the accumulation of wiring harnesses caused by excessive length. For the movement of the wire harness, it is necessary to add a fixed structure with rubber ring buffer and guide groove to avoid scratching the wire harness with other components, which may cause damage to the wire harness.

During the wiring harness layout process, EMC electromagnetic interference factors should be considered, and shielded high-voltage cables should be used to avoid high-frequency noise emission. High and low voltage cables must be arranged separately to avoid mutual interference caused by cross overlapping of wiring harnesses.

Considering the aesthetics of the wiring harness layout, the direction should be consistent with the direction according to the attachment, avoiding oblique directions. For the wiring harness in the engine compartment, it is best to route it below or inside the structural components or components. The exposed high-voltage wiring harness at the bottom of the vehicle should be shielded and protected by protective tubes and plates.

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