High-voltage Wiring Harness for Connector Performance Requirements

Electrical performance requirements. 

The rated voltage of the connector should meet the voltage requirements of new energy vehicles. Considering the high-voltage system types of new energy vehicles, the rated voltage of the connector should be above 200 V to ensure safe and stable operation under high-voltage conditions. Insulation resistance is an important indicator for measuring the electrical performance of connectors. To ensure that the connector does not leak or short-circuit under high-voltage conditions, its insulation resistance should comply with relevant standards, such as 100 MΩ. The withstand voltage performance of the connector should be above 1 000 V to ensure safe operation in the high-voltage system of new energy vehicles.

Mechanical performance requirements.

The plug-in and pull-out force of the connector is an important indicator for measuring its ease of use. In order to facilitate operation and not be too loose during plug-in and pull-out, the plug-in and pull-out force is required to be within the specified range and should not be greater than 100 N. The mechanical life of the connector refers to the number of times it can be plugged and unplugged normally, and whether it can maintain stability and reliability in long-term use. Generally, its mechanical life is required to be more than 50 plug-in and unplug operations. Because new energy vehicles will generate vibration during driving, the connector should have good anti-vibration performance. Under the specified frequency amplitude, the electrical and mechanical properties of the connector should not be affected.

Temperature adaptability requirements. 

The connector works normally in a wide temperature range. The temperature adaptability requirements are within the range of -40~125 ℃, and the electrical and mechanical properties of the connector are not affected, as shown in Table 1.

Anti-corrosion performance requirements. 

The selection of connector materials is related to its anti-corrosion performance. The shell is preferably made of metal materials with excellent corrosion resistance, such as aluminum or zinc alloy, and the surface can be sandblasted. The contact part is made of copper, and gold plating, silver plating, nickel plating and other processes are used to improve its conductivity while meeting the anti-corrosion requirements. The connector should have good sealing performance to prevent the intrusion of harmful substances such as moisture and dust, and effectively avoid corrosion. The sealing structure should be well designed during design to ensure that the sealing effect is maintained in various harsh environments. A layer of anti-corrosion coating can be applied to the surface of the connector to enhance its anti-corrosion performance and ensure that the connector is tightly plugged in and not easy to loosen. Special sealing can be used to ensure that the connection is not corroded by moisture and corrosive substances. Regular maintenance and inspection of the connector is an important measure to ensure its long-term anti-corrosion performance.