Wiring harness and connectors for automotive high Voltage
What is a High Voltage Wiring Harness?
In an electric vehicle, the high-voltage wiring harness is the electrical conduit that carries power between the vehicle’s high-voltage battery, high-voltage motor, and various high-power systems. This harness’s functionality significantly differs from conventional vehicle harnesses because most conventional vehicles operate between 12V and 48V. In contrast, electric cars work between 300V and 1,000V. This creates challenges for the automobile industry regarding designing such products for optimal performance.
Functionality and Key Components
The HV wiring harness is the main artery of power distribution in EVs. It connects essential components like the battery, electric motor, onboard charger, and inverter. Here’s how each component interacts within the EV system:
Table: Voltage and Current Ranges in Key EV Components
| System Component | Voltage Range | Current Range |
|---|---|---|
| Battery Pack | 400V – 800V | 100A – 300A |
| Electric Motor | 400V – 800V | 50A – 300A |
| Onboard Charger | 240V – 500V | 20A – 60A |
| Inverter | 400V – 800V | / |
This high-voltage wiring enables EVs to efficiently manage and deliver power, ensuring smooth acceleration, battery charging, and overall energy management.
Materials and Design Requirements
High-voltage wiring harnesses must withstand various environmental conditions, including extreme temperatures, vibrations, and chemical exposure. The insulation materials used for these harnesses are critical to their durability and safety.
Table: Common Insulation Materials in HV Wiring Harnesses
| Insulation Material | Temperature Resistance | Mechanical Strength | Chemical Resistance |
|---|---|---|---|
| Cross-linked Polyethylene (XLPE) | -40°C to 125°C | High | Excellent |
| Silicone Rubber | -60°C to 200°C | Moderate | Excellent |
| Polyvinyl Chloride (PVC) | -40°C to 105°C | Low | Good |
These materials help protect the conductors from short circuits, electrical faults, and mechanical wear and tear.
Common Issues and Solutions
Even with the best designs, high-voltage wiring harnesses can encounter issues. Below are some common problems and solutions:
Overheating: Ensure that the cables are rated for the current they need to carry and that enough thermal management is provided.
Insulation Wear: Periodic inspections and good-quality insulation materials can avoid premature degradation.
Corrosion: Proper sealing and waterproofing methods will keep the moisture and chemicals away from corrosion.
Real-World Cases
Case Study 1: Tesla Model 3
The wiring harness for high voltage in the Tesla Model 3 is an innovative design that connects different cables to achieve a perfect connection between the battery pack and the electric motor. This is possible using the latest materials and Tesla’s very accurate engineering. Indeed, this harness will not only deliver power but also do so with minimum weight. Because Tesla optimized this design, there was an improvement in the range for which the vehicle would operate, as well as the general performance. This is just excellence in design that can drive tremendous results for electric vehicle technology.
Case Study 2: BMW i3
In the BMW i3, the high-voltage wiring harness includes a state-of-the-art battery management system that monitors the status of the battery in real-time. The key aspect of this design is the lightweight approach, high strength, low-weight material used to meet the efficiency needs of the vehicle. BMW has also initiated a modular design for its wiring harness to make it easily maintained and replaced when required. Such thoughtfulness does not just increase the maintainability of the vehicle but also keeps it, leading to electric mobility.
Future Trends in High Voltage Wiring Harnesses
The development of electric vehicles raises increasing demands for high-voltage wiring harnesses. Consequently, manufacturers would focus on making the system lightweight, efficient, and environmentally stress-resistant.
Innovations include new composite materials for insulation, increased integration of sensors for real-time monitoring, and efforts to reduce the weight and bulk of the wiring systems to improve vehicle efficiency.
High Voltage Wiring Harness Solution
Gvtong Electronics is a one-stop source for electric vehicle high voltage cable harness assembly, low voltage cable harness assembly and electrical connectors.
We provide electric vehicle high voltage cables and harness assemblies. Our products are used in the automotive industry as well as other industries.
High-Voltage Interconnection Systems for Hybrid & Electric Vehicles
Jvtong’s high-voltage interconnection portfolio helps enable automotive OEMs and suppliers to flourish in the fast-changing electric mobility market while continuing the industry momentum to electrify the powertrain. Our products enable the electrical connections needed to safely, efficiently and reliably make sustainable emobility a reality. Our broad line of high voltage terminal and connector systems includes a complete range of interfaces required in hybrid and electric vehicles.
What Services Gvtong Provide
1) Full range of EV HV connectors for safe, reliable and efficient interconnection. We have strong resource integration capabilities and the lowest price advantage. Whatever you need, we can supply.
2) Provide wire harness processing services.
If you have materials such as connectors and cables, but do not have the ability to process and produce finished wire harnesses, we can provide a full range of processing and production services. The most advanced crimping process ensures that the high-voltage wire harness can be used 100% safely for the reliable connection of high-voltage components in the EV.
3) Full customized supports on all your high voltage interconnection requirements
Gvtong Electronics offers a complete line of high voltage cables for electric vehicles and hybrid electric vehicles.
The cables are capable of carrying up to 1500V of voltage, which is more than enough for most electric vehicles. Our high voltage cable assemblies include unshielded cables , shielded cables and multi-core cables.
The cables are available in different sizes, lengths and configurations to meet the needs of your application.
Electric Vehicle High Voltage Cables
Jvtong Electronics offers a complete line of high voltage cables for electric vehicles and hybrid electric vehicles.
The cables are capable of carrying up to 1500V of voltage, which is more than enough for most electric vehicles. Our high voltage cable assemblies include unshielded cables , shielded cables and multi-core cables.
The cables are available in different sizes, lengths and configurations to meet the needs of your application.
Jvtong’s High Voltage Wire Harness Assemblies Ensure Safe Interconnection of EVs
Jvtong provides high quality cable harness assemblies for your applications that require extra protection from the elements or harsh environments such as extreme temperatures or high humidity levels.
The safe and reliable high voltage harness assemblies are combined with the most advanced technologies such as high voltage interlock loop (ensures safe interconnection between EV batteries and charge controllers), electromagnetic shielding (provides protection against electromagnetic interference) and mechanical shock response (protects against sudden impacts during road collisions or off-road driving conditions), to ensure safe interconnection of EVs.
EV High Voltage Interconnection Solution
High Voltage Interconnection Solutions are the connectors used to connect the high voltage components in Electric Vehicles. Jvtong offers a wide range of High Voltage Connectors for EV, HEV and PHEV applications.
Jvtong Electronics offers a full line of high voltage connector series from 1kV to 4kV with more than 20 standard product models, including both non-insulated and insulated types, both metal connectors and plastic ones. Our products have been widely applied in HV power supplies for electric cars, hybrid cars, RVs, electric trucks, vans, battery electric buses, coaches, other public transportation vehicles, agricultural and construction equipment all over the world.
Jvtong brand has become synonymous with quality HV connectors in the EV industry. We have built our reputation on providing safe and reliable connections that last through years of use in extreme environments. Our connectors are used in Electric Commercial Vehicles, Electric Passenger Vehicles and other applications requiring safe connection of HV components such as PDU, Motor, MCU, DC-DC Converter, OBC, PTC, AC etc.
Jvtong EV High Voltage Interconnection Solution for Electric Commercial Vehicles is a complete set of devices which provides safe connection between Electric Commercial Vehicles and Electrical Distribution System.
Jvtong Electronics, Top Manufacturer of EV HV Connectors
We have been designing and manufacturing electric commercial vehicle high voltage connectors for more than 15 years. We have developed and produced a wide range of electric vehicle connector solutions for industrial vehicles, commercial vehicles, electric buses and passenger vehicles. With decades of experience in electric vehicle industry and strong technical background, Guchen Electronics is one of the leading manufacturers of high voltage connectors in China.
Electric Passenger Vehicle High Voltage Interconnection Solution
We supply high quality connectors for safe power distribution and control in your electric vehicles. Our high voltage connectors are designed to withstand the harsh conditions of industrial applications, including high temperature and vibrations. The connectors are also resistant to chemicals and corrosion in order to ensure long-term durability.
Jvtong High Voltage Connectors with Strict Quality Control
Our products are used extensively in the EV industry and have been tested according to international standards. We can also provide you with customized solutions that meet your specific requirements. With over 15 years’ experience in the field of high voltage connectors, we have built up a comprehensive range of solutions for safe power distribution and control in your electric vehicles (EV). We have cooperated with many well-known domestic and foreign partners.