7165-1198 Automotic Waterproof Plug Silicone Rubber Seal For Auto Connector

Pure electric vehicles include both high-voltage and low-voltage wiring harnesses in the entire vehicle wiring harness. From the perspective of EMC shielding design and development, when selecting shielded cables, it is not only necessary to consider their shielding performance, shielding mesh density, but also mechanical strength, environmental impact, and other characteristics. When the entire cable is affected by too much mechanical, weather, and humidity, the shielding at the connection will be most severely affected. High voltage connectors should also choose metal connectors or plastic connectors with shielding function.

Each interface of the high-voltage wiring harness adopts shielding treatment, and the front and rear motor interfaces are crimped with shielding snap rings and electrical box rails. The controller and battery box connectors use structural components with shielding function. At present, there is no detailed standard for this aspect in China, and most manufacturers add magnetic rings to relevant high-voltage components, including equipment and wiring harnesses.

A magnetic ring is a circular magnet, which is a commonly used anti-interference component in electronic circuits and has a good suppression effect on high-frequency noise. The magnetic ring has different impedance characteristics at different frequencies, and the impedance is generally very small at low frequencies. When the signal frequency increases, the impedance of the magnetic ring increases sharply. So under the action of the magnetic ring, for the high-voltage wiring harness of the high-voltage system, the magnetic ring should be as close as possible to the inlet and outlet of the high-voltage wiring harness of the motor and controller. It can effectively suppress the passage of high-frequency interference signals.

High Voltage Interlock Loop (HVIL) refers to the use of low-voltage electrical signals to check the electrical integrity of the entire high-voltage module, wires, and connectors.

When the interlock malfunctions, it is necessary to ensure that the entire vehicle's high-voltage system is powered off and cannot be powered on until the fault is resolved, while triggering corresponding warning signals.

When the high-voltage circuit with a high-voltage module is disconnected, it is necessary to prevent personnel from coming into contact with live parts and causing electric shock accidents due to capacitive loads in the high-voltage circuit (the DC voltage must be reduced to no more than 60Vd. c within the specified time, or the total energy stored in the B-level circuit is less than 0.2J).

When the high-voltage circuit with the high-voltage module is disconnected, prevent electric shock accidents caused by personnel coming into contact with live parts due to the electrification of high-voltage cables and accidental electrification of the entire vehicle.

During use, prevent local heating and arcing caused by human operation issues, vehicle bumps, product aging, line wear, etc., which can lead to a sharp decline in product performance, fire accidents, and ensure vehicle and personal safety.

High voltage safety HVIL1. Development process

The development of high-voltage wire harnesses should complement the entire vehicle development process, as shown in Figure 2.

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