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Preparation for high-voltage wire harness production process

1.1 Composition of high-voltage lines

The high-voltage wiring harness includes: high-voltage wire, high-temperature corrugated pipe, high-voltage connector or grounding, heat shrink tubing, and labels.

1.2 Selection of high-voltage lines

According to the requirements of the drawings, wires are selected. Currently, high-voltage harnesses for heavy-duty trucks mostly use cables with a rated voltage of AC1000/DC1500; Heat resistance level -40~125 ℃; It has the characteristics of flame retardancy, halogen-free, and low smoke; Double layer insulation with a shielding layer, and the outer insulation layer is orange. The arrangement order of the model, voltage level, and specification composition of high-voltage wire products is shown in Figure 1:

1.3 Selection of high-voltage connectors

A high-voltage connector that meets the selection requirements and meets a series of electrical parameters such as rated voltage, rated current, contact resistance, insulation resistance, withstand voltage, environmental temperature, and protection level. After the connector is made into a cable component, it is necessary to consider the impact of vehicle and equipment vibration on the connector or contact parts. Reasonable wiring and fixation of the cable component should be carried out based on the actual installation position of the wire harness on the vehicle.

The specific requirement is that the cable components should run straight out from the tail end of the connector, and the first fixed point should be set within 130mm to ensure that there is no relative displacement such as shaking or movement between the fixed point and the equipment end connector. After the first fixed point, it should be fixed at intervals of no more than 300mm, and the cable bends should be fixed separately. Moreover, during the assembly of cable components, the wiring harness should not be pulled too tightly to avoid pulling between the fixed points of the wiring harness when the vehicle is in a bumpy state, which can lead to stretching the wiring harness and causing virtual connections or even wire breakage inside the wiring harness.

Simple instructions：

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