How do new energy wiring harnesses ensure vehicle electrical safety through high-voltage insulation design?
Publish Time: 2025-11-11
With the rapid development of new energy vehicles, high-voltage electrical systems have become a core component of vehicle power and control. As the "neural network" connecting key components such as batteries, motors, and electronic controls, new energy wiring harnesses play a crucial role in vehicle electrical safety. High-voltage insulation design is one of the key technologies to ensure the safe and reliable operation of wiring harnesses.1. Selection of High-Performance Insulation MaterialsHigh-voltage wiring harnesses typically operate at voltages between 300V and 1000V, far exceeding the 12V or 24V systems of traditional gasoline vehicles. Therefore, higher requirements are placed on insulation materials. High-quality insulation materials must possess excellent dielectric strength, heat resistance, aging resistance, and flame retardant properties. Currently, mainstream new energy wiring harnesses mostly use materials such as cross-linked polyethylene, thermoplastic elastomers, or fluoroplastics. These materials not only maintain stable insulation performance under complex conditions such as high temperature, high humidity, and oil contamination, but also effectively prevent corona discharge and localized breakdown, thereby significantly improving the safety of the vehicle's high-voltage system.2. Multi-layer Composite Structure DesignTo cope with extreme environments and mechanical stresses, high-voltage wiring harnesses in new energy systems generally adopt a multi-layer composite structure design. A typical structure includes a conductor layer, an inner insulation layer, a shielding layer, and an outer insulation sheath. The inner insulation layer directly wraps the conductor, providing the primary electrical isolation function; the shielding layer suppresses electromagnetic interference and provides an additional protection path in the event of insulation failure; the outer sheath possesses wear-resistant, tear-resistant, and chemical corrosion-resistant properties, preventing external damage from causing internal insulation failure. This "multi-protection" design concept significantly improves the reliability of the wiring harness in real-world application scenarios such as collisions, vibrations, and bending.3. Precision Manufacturing and Process ControlHigh-voltage insulation performance depends not only on materials and structure but also on precise manufacturing processes. During wiring harness production, the temperature, speed, and tension control of the extrusion process directly affect the uniformity and density of the insulation layer. The presence of bubbles, impurities, or uneven thickness can easily lead to partial discharge points under high voltage, ultimately causing insulation breakdown. Therefore, high-end wiring harness manufacturers generally introduce automated production lines and online testing systems to monitor key parameters such as insulation thickness, concentricity, and surface defects in real time, ensuring that every section of wiring harness meets stringent insulation standards.4. Rigorous Testing and Verification SystemTo verify the effectiveness of the high-voltage insulation design, new energy wiring harnesses undergo a series of rigorous testing procedures, including but not limited to: withstand voltage testing, insulation resistance testing, thermal aging testing, salt spray testing, and bending fatigue testing. Furthermore, OEMs simulate real-world operating environments and conduct vehicle-level high-voltage safety assessments, such as IP protection level testing and high-voltage interlock function verification. Only after passing all tests can the wiring harness be approved for use in mass-produced vehicles, thus eliminating potential electrical safety hazards at the source.In summary, new energy wiring harnesses construct a complete high-voltage insulation safety assurance system through four dimensions: high-performance insulation materials, multi-layer composite structures, precision manufacturing processes, and comprehensive testing and verification. This not only effectively prevents risks such as leakage, short circuits, and arcing but also provides a solid foundation for the efficient, stable, and safe operation of new energy vehicles.
