Digital interpretation: the key technology of automobile EV high voltage line

# Digital interpretation: the key technology of automobile EV high voltage line

With the rapid development of the new energy vehicle industry, electric vehicles (Electric Vehicle, referred to as EV) as an important member of it, its high-voltage wiring harness as the core component of energy transmission, its key technology has received increasing attention both inside and outside the industry. This paper will deeply discuss the key technology and its importance of EV high voltage line through digital interpretation.

## Basic overview of 1. high-voltage wiring harness

The high-voltage wiring harness is an important component that connects the power battery, the motor, the controller and other high-voltage components inside the electric vehicle, and is responsible for the efficient and safe transmission of electric energy. According to the power requirements and safety standards of electric vehicles, the design of high-voltage wiring harnesses needs to comprehensively consider many aspects such as conductivity, insulation, electromagnetic shielding and wear resistance. Generally speaking, the working voltage of the high-voltage system in the EV can reach hundreds of volts, and the current may reach tens or even hundreds of amperes. Therefore, the technical content and safety requirements of the high-voltage wiring harness are extremely high.

##2. Key Technology Analysis

### 1. Material Selection

The conductor material of the high-voltage wire harness is mostly copper or copper alloy with high conductivity to ensure the low loss transmission of electric energy. At the same time, the choice of insulating materials is also critical, and it needs to have the characteristics of high temperature resistance, high pressure resistance, and corrosion resistance to ensure electrical safety and stability under extreme conditions. For example, the development of new insulation materials, such as polyimide (PI) and cross-linked polyethylene (XLPE), has significantly improved the temperature resistance and insulation strength of high-voltage wiring harnesses.

### 2. Harness structure design

**Multi-strand filament stranding technology**: High-voltage wiring harnesses for vehicles are usually made of multiple thin copper wires stranded. This design not only increases the cross-sectional area of the conductor, reduces the resistance, but also uses the "skin effect" Improve the conductive efficiency. At the same time, filament stranding also enhances the flexibility and bending resistance of the harness, making it more adaptable to complex vehicle wiring environments.

**Shielding layer design**: In order to prevent electromagnetic interference, high-voltage wiring harnesses are usually equipped with shielding layers, including aluminum foil shielding and braided shielding. These shielding layers can effectively reduce electromagnetic radiation, protect the vehicle electrical system from external interference, and ensure the stability and accuracy of signal transmission.

### 3. Connector Technology

High-voltage connector is an important interface between high-voltage wiring harness and high-voltage components, and its performance directly affects the safety and reliability of the entire high-voltage system. The high-voltage connector shall be equipped with high-voltage interlock (HVIL) function to ensure that the power terminal and interlock terminal can operate according to specific timing during the connection and disconnection process to avoid the risk of arcing and electric shock. In addition, the terminal retention aid (TPA) and the locking device (CPA) of the connector are also important, which can prevent the connector from accidentally loosening or poor contact during the driving of the vehicle.

### 4. Safety Design

**Overvoltage protection and overcurrent protection**: High-voltage wiring harness systems need to be integrated with overvoltage protection and overcurrent protection functions. Once an abnormal voltage or current is detected, immediate measures will be taken to cut off the circuit to prevent equipment damage and safety accidents.

**Insulation monitoring and temperature control**: Real-time monitoring of the insulation status and temperature of the high-voltage wiring harness. Once the insulation is damaged or the temperature is too high, an alarm will be issued immediately and corresponding protective measures will be taken to ensure the safety of vehicle operation.

##3. Technology Development Trend

### 1. Lightweight and Integrated

With the advancement of material science and the improvement of manufacturing processes, the lightweight and integration of high-voltage harnesses have become an important trend in the future. By adopting new lightweight materials and optimizing structural design, the weight and volume of the wiring harness are reduced, and the energy efficiency and cruising range of the vehicle are improved.

### 2. Intelligence and Networking

With the development of intelligent network technology, high-voltage wiring harness will be more intelligent and networked. By integrating sensors and communication modules, the remote monitoring and fault diagnosis of high-voltage systems are realized, and the reliability and maintenance efficiency of the system are improved. At the same time, the high-voltage system will more closely interact with other systems such as vehicle control systems and energy management systems to form a more intelligent automotive ecosystem.

### 3. High energy density and efficient transmission

Improving the energy density of batteries and the transmission efficiency of high-voltage systems is an important direction for the development of new energy vehicles. By developing new electrode materials, optimizing battery structure and control algorithms, the battery energy density can be improved and the high-voltage system can be efficiently transmitted, and the cruising range and power performance of electric vehicles can be further increased.

##4. epilogue

Automotive EV high-voltage wiring harness is one of the core components of electric vehicles, and its key technologies involve material selection, wiring harness structure design, connector technology, and safety design. With the continuous development of the new energy vehicle industry and the continuous innovation of technology, the high-voltage wiring harness will develop in the direction of lightweight, integrated, intelligent and networked, providing a strong guarantee for the safe and efficient operation of electric vehicles. In the future, we have reason to believe that high-voltage wiring harness technology will continue to break through and contribute more to the sustainable development of the new energy automobile industry.