New energy vehicle wiring harness layout scheme and EMC protection

       In response to the national call for energy conservation and emission reduction, major automobile manufacturers have launched different types of new energy vehicles and applied advanced manufacturing technologies to convert the power source of vehicles from traditional fuels to electricity. The design and application plan of the whole vehicle high-voltage wiring harness mainly involves the direction of the wiring harness, the selection method of the path, the type of high-voltage connector, the selection of the charging port, the shielding design, the wiring groove design, etc. (Test system for new energy vehicles).

       1. Wire Harness Design Scheme

       1). High-voltage wiring harness design scheme

       The high-voltage wiring harness can provide high-voltage power for new energy vehicles, and its wiring harness design has extremely important significance. The following principles should be followed during the design process. First, for the direction and path design of the wiring harness, the high-voltage wiring harness design should adopt a dual-track system. At this time, the high-voltage electricity generated by the operating system has exceeded the range of the human body, and the body cannot be used as a grounding point for the whole vehicle. Second, for the selection of the connector, the connector is mainly connected to high-voltage current and is responsible for the safety of humans and machines in the operation of the high-voltage loop. Therefore, the designer should choose a high-voltage connector with high-voltage resistance, good waterproof effect, and tightly connected shielding. Third, for shielding design. The designer should choose a high-voltage line with better shielding performance, and wrap the shielding net directly inside the high-voltage line. When installing the connector, it is necessary to ensure that the shielding layer is completely connected.

       2).Low-voltage wiring harness design scheme

       The design scheme can be divided into the following steps: one is to design the route of the wiring harness, the other is to select the fixed buckle of the line, the third is to carry out shielding design, and forty to choose the connector. The low-voltage wiring harness based on this design scheme not only has the functions of a traditional car, but also realizes the function of an electronic control unit module. In the overall design process, designers should focus on the interference caused by high-voltage wiring harnesses, and follow the principle of configuring different low-voltage wires for different signal sources.

       High-voltage connectors are mainly divided into two types: shielded and unshielded. The internal structure of the unshielded connector is relatively simple. The installation cost of the shielding function is saved, and it can be applied to parts that do not need the shielding function, such as the charging circuit, the inside of the controller, and the electrical appliance with a metal shell. Shielded connectors are the opposite, and are suitable for applications that require shielding functions such as high-voltage wiring harness connections. Any type of connector needs to have a waterproof function, and the connection position is different, and the waterproof level of the selected connector is also different.

       3). High and low voltage wiring harness layout plan

       This layout plan mainly involves the following links. The engine compartment and its wiring harness layout plan belongs to the entire vehicle model. It is the difficult and key point of the design work. It concentrates the connecting wiring harness of the drive motor, PDU and other equipment, and the cab. The design of this link is aimed at In terms of the non-straight structure of traditional vehicles, the luggage compartment involves wiring harness units such as high-voltage lines, battery control systems, and on-board systems.

       2. EMC protection of new energy vehicles

       Whether it is a pure electric vehicle or a hybrid vehicle, it is powered by a power source to provide the vehicle with operating energy. How to realize the application of high-voltage wiring harness in the protection design of the entire vehicle EMC test system is a difficult problem faced by many designers. It can be seen in the EMC protection design of the vehicle that the radiation conduction design is the key research direction, so the designer should consider this factor at the beginning of the plan.