Role and safety standards Core Role: Power transmission: supply power to engine, lights, air conditioning and other equipment. Signal transmission: connects ECU, sensors and actuators to realize vehicle control functions. Safety Standard: Material standards: need to meet the requirements of high temperature resistance, flame retardant, low smoke and non-toxic (such as UL certified materials). Structural standards: the thickness of the insulation layer, the wiring harness arrangement needs to comply with the specifications to avoid short circuit. Safety performance: automatically cut off the power supply in case of failure (e.g. fuses, circuit breakers) to prevent fire. Environmental standards: low-sulfur and low-halogen materials to reduce environmental pollution. Fourth, fault diagnosis methods Intuitive inspection method: Observe whether the wiring harness is broken, aging, smell whether there is a burning smell, touch whether overheating. Instrumentation detection: Multimeter: measure the voltage, resistance, determine the break or short circuit. Oscilloscope: detect the signal waveform, locate the source of interference. Tool-assisted method: Test light method: quickly detect whether the wire is energized. X-ray non-destructive testing: internal imaging, observe whether the terminal crimping is loose. Fifth, the special characteristics of the new energy vehicle high-voltage wiring harnesses Classification and function: Power battery high-voltage cable: connects the battery with the high-voltage control box. Motor controller cable: transmits motor drive power. Fast charging/slow charging harness: connects the charging interface with the vehicle charger. High-voltage accessory harness: supply power to air conditioning compressor, DC/DC converter, etc. Performance Requirements: High voltage resistance: rated 600V AC/900V DC for passenger cars, higher for commercial vehicles. High current resistance: 250A~400A, some motor harnesses need higher specifications. Shielding performance: shielding layer to reduce electromagnetic interference (EMI/RFI), to ensure signal stability.
Automotive Power Connection Harness Show
2025 03/21