Overview of the process innovation and development of new energy high-voltage wire harnesses

Description: With the global emphasis on environmental protection and the increasing scarcity of oil resources, the development of new energy vehicles has become an important trend in the global automotive industry. As the core component of power transmission in new energy vehicles, the process technology of high-voltage wire harnesses not only affects the performance of the vehicle, but also directly affects the safety, reliability and service life of the entire vehicle.

Introduction: Today, the manufacturing process of high-voltage wire harnesses is part of the new technology, which is determined by a high level of manual work, with up to 85% of the manufacturing added value. The rationalization potential presented by manufacturing automation has not yet been fully utilized. Nevertheless, automation is a key driver to meet all the requirements of the transformation of the manufacturing industry.

Electric vehicles are a fundamental change in the automotive industry, characterized by a sharp increase in the sales of electric vehicles and the need for new technologies. These are all related to the increasing quality requirements and financial pressures.
The protagonists of new energy vehicles are high-voltage connectors and high-voltage wires. The high-voltage connector for new energy vehicles is a mechatronic product consisting of four parts: contacts, insulators, housings and accessories. Among them, the contact is the core part of the connector, completing the connection of optical signals and electrical signals. The vehicle needs to complete the connection of vehicle optical signals and electrical signals through the plugging of contacts. Insulators and shells mainly play the role of fixed insulation and mechanical protection.

The manufacturing process integrates multiple technologies such as electrical performance design, CNC machining, stamping process technology, plastic stamping process technology, precision die-casting process technology, and strict testing methods.
The quality and precision of high-voltage connector products directly affect the electrical, mechanical and environmental performance of the connector, and thus affect the safety of electric vehicle driving. Therefore, the quality requirements and manufacturing precision of high-voltage connectors are relatively high, and they belong to the connector field of high-end products with high added value.

In the new energy vehicle industry, high-voltage connectors are extremely important components. They are used in both complete vehicles and charging facilities. The main application scenarios of high-voltage connectors in complete vehicles include DC, water-heating PTC chargers, wind-heating PTC, DC charging ports, power motors, high-voltage wiring harnesses, maintenance switches, inverters, power batteries, high-voltage boxes, electric air conditioners, AC charging ports, etc.

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