Compared with traditional automotive cables, the high-voltage cable of new energy vehicles are significantly different in many aspects, which mainly due to the significant changes in the operational environment.

First of all, the high-voltage cables of new energy vehicles face the challenge of high voltage and high current. On-board cables need to be able to withstand currents of up to 600/300A, which is in sharp contrast to the 12V battery voltage commonly used in fuel vehicles and conductors with voltage levels less than 60V.

Secondly, high-voltage wiring harnesses of new energy vehicles have the characteristics of large wire diameters and a large number of cables. In order to meet the needs of electrical structures such as high-voltage battery frequency transformers, low-voltage batteries, air conditioning compressors, electric heating, and power distribution units, a large number of cables need to be configured in a limited space.

In addition, the use of high-voltage wiring harnesses for new energy vehicles in exposed Spaces also puts higher requirements on their performance. In particular, the cable of the charging gun part, which has been in the outdoor environment for a long time, has strict requirements on its weather resistance, wear resistance, bending resistance and tear resistance.

Due to these characteristics of the high-voltage wiring harness in the car, its design process faces multiple challenges such as wiring, safety, shielding, weight and cost.

In terms of wiring, the layout of high-voltage wiring harnesses for new energy vehicles needs to follow a series of specifications. For example, under static load, the outer diameter of the wire should be 4 times the minimum turning radius; Under dynamic load, it is 8 times. At the same time, the distance between high and low voltage wires should be maintained at more than 100 mm, and the distance from the end of the high voltage connection wire to the initial fixed point should not exceed 100 mm, while the distance between the adjacent fixed points is generally controlled within 150~200 mm. In addition, the high-voltage wiring harness should be arranged at the bottom of the car as far as possible to reduce the occupation of the internal space of the vehicle.

In terms of safety, high voltage and high current put forward strict requirements for insulation performance. Therefore, the choice of wire material is very important. For example, high voltage wires of 600V or 900V (AC) and wires with wall thickness between 0.6 mm and 1.1 mm can be selected. At the same time, these wires should also have excellent heat resistance, such as silicone rubber cord and cross-linked polyethylene cross-linked polyolefin materials, to ensure that they can maintain stable performance in high temperature environments.

In terms of electromagnetic shielding, high-voltage wire harnesses need effective electromagnetic shielding measures to reduce electromagnetic noise and electromagnetic interference. This is mainly due to the electromagnetic field noise generated by high voltage and large AC current and the electromagnetic interference generated when the electrical components are quickly powered off.