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The automotive wiring harness is the network backbone of the vehicle's electrical system, connecting electrical and electronic components and enabling them to function; without the harness there is no vehicle electrical circuit. Conventional vehicles mostly use low-voltage harnesses, while the growth of new energy vehicles has driven rapid development of high-voltage harnesses. A new energy vehicle high-voltage harness consists mainly of connectors, terminals, wires and coverings, and carries power transmission for high-voltage system components such as the traction battery, charger, DC charging port, AC charging port, service switch, air conditioning, electric drive and motor.
The harness supply chain includes cables and wires, connectors, processing equipment, harness manufacturing and downstream applications. Harnesses are used very widely, in vehicles, electrical products, computers and communication equipment and various electronic instruments; the body harness connects the whole body and is roughly H-shaped. Because in-vehicle high-voltage harnesses carry high voltage and current with large conductor diameters and many wires, harness design faces challenges in routing, safety, shielding, weight and cost.
Main test items
1. Environmental reliability: high temperature, low temperature, thermal shock, temperature-humidity cycling, vibration, combined temperature-humidity-vibration, salt spray, ageing, sealing, chemical corrosion, battery fluid resistance and gas corrosion.
2. Electrical performance: insulation resistance, dielectric strength, current cycling, repeated connect/disconnect life, contact resistance (voltage drop), temperature rise, flame resistance and continuity.
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