A high sealing requirement based on hybrid vehicle transmission cylinder wire harness

Abstract

The application provides a hybrid vehicle gearbox cylinder-penetrating wire harness based on high sealing requirement, which comprises a wire and a connector, terminals are respectively crimped at both ends of the wire, the terminals are inserted into the connector to form an electrical connection, a sealing element is arranged on the side of the wire close to the terminal, the terminal is located between the sealing element and the connector, the sealing element and the connector are crimped to form a cavity between the sealing element, the wire and the connector, and the sealing element effectively seals and protects the terminal, the hybrid vehicle gearbox cylinder-penetrating wire harness based on high sealing requirement has the beneficial effects of high sealing property, high reliability and resistance to harsh environment, and meets the severe use requirements of the gearbox cylinder-penetrating wire harness.

Description

Technical Field

[0001] This invention relates to the field of automotive wiring harness technology, and in particular to a hybrid vehicle transmission through-cylinder wiring harness based on high sealing requirements. Background Technology

[0002] With the rapid development of the automotive industry towards electrification and intelligentization, the transmission systems of hybrid and pure electric vehicles place higher demands on the reliability and sealing performance of electrical connections. In existing technologies, automotive transmission wiring harnesses typically employ externally sealed cylinder connectors, achieving basic protection through sealing rings or potting compound on the outside of the connector. However, this design has significant limitations: the internal electrical interfaces, cable connection points, and signal transmission channels of the connector often lack effective sealing protection. This leads to problems such as moisture intrusion, signal interference, and poor contact under complex operating conditions such as high temperature, high humidity, and vibration, ultimately affecting the stability of the transmission control system and the overall vehicle safety.

[0003] Especially in the complex powertrain systems of hybrid vehicles, the transmission needs to simultaneously handle signal transmission tasks from multiple sources, including the motor controller, sensor network, and solenoid valve actuators, placing stringent requirements on the sealing level and environmental interference resistance of the wiring harness. Existing technologies often compensate for insufficient internal sealing by adding external sealing structures when meeting IP67 and higher protection requirements. However, this approach not only increases manufacturing costs but may also lead to increased assembly complexity and maintenance difficulties.

[0004] Therefore, there is an urgent need for a through-cylinder wiring harness technology that can meet the stringent requirements of high sealing performance and high reliability for hybrid vehicle transmission systems, while also taking into account cost control and ease of assembly. Summary of the Invention

[0005] In view of the above, the present invention provides a hybrid vehicle transmission cylinder wiring harness based on high sealing requirements. Through high-performance sealing structure design, it effectively solves the technical problems of incomplete sealing and insufficient protection level in the prior art, and has high industrial application value.

[0006] The present invention specifically adopts the following technical solution: a hybrid vehicle transmission cylinder-through wiring harness based on high sealing requirements, comprising a wire and a connector. Terminals are crimped to both ends of the wire, and the wire is inserted into the connector through the terminals to form an electrical connection. A sealing element is provided on the side of the wire near the terminal, and the terminal is located between the sealing element and the connector. The sealing element of the present invention can be detachably configured, for example, the sealing element can be sleeved or clamped onto the wire. Besides being located on the wire, the sealing element can also be located on the inner circumference of the connector interface, or simultaneously on the wire and the inner circumference of the connector interface. If the sealing element is located on the wire, it will be inserted into the connector along with the terminal, forming a sealed protection for the terminal. The sealing element and the connector are crimped together, so that the terminal is located in the space between the sealing element, the wire, and the inner interface of the connector, thus forming a sealed protection for the terminal.

[0007] As a further improved technical solution, multiple terminals are located between the seal and the connector, integrating multiple independent terminals into a connector housing and being completely sealed by one or a group of integrated seals. This improves the integration level of the through-cylinder wiring harness, which is conducive to the miniaturization and weight reduction of the whole machine. It forms a continuous and uninterrupted sealing interface, eliminating the "short plank effect" caused by installation process deviations, differences in sealing ring quality, and uneven shell flatness between multiple independent sealing points. At the same time, it has excellent vibration and shock resistance, simplifies assembly and improves efficiency, enhances electrical performance and signal integrity, and strengthens environmental resistance.

[0008] As a further improved technical solution, the connector includes a pin connector and / or a resolver sensor connector to provide high-performance sealing protection for the terminals inside the pin connector and resolver sensor connector located above and susceptible to oil splashes. The pin connector can be one of a 12-pin connector, an 18-pin connector, a 20-pin connector, a 36-pin connector, or other pin connectors.

[0009] As a further improved technical solution, the connector also includes a gearbox in-cylinder sensor connector and / or a solenoid valve sensor connector, used to seal and protect the terminals in the gearbox in-cylinder sensor connector and the solenoid valve sensor connector.

[0010] As a further improved technical solution, the seal includes several protrusions, which are at least one of the following shapes: sawtooth, wave, zigzag, and arc. The seal may include multiple rings of protrusions, and the protrusion structure can be more tightly pressed into the wires and connectors, effectively preventing external contaminants from entering the terminal connection area.

[0011] As a further improved technical solution, multiple seals can be included. These seals can have identical or different structures, and can be arranged laterally or longitudinally. The combination of multiple seals enhances the sealing performance and stability of the connector and terminal. Different seals can perform completely different sealing tasks. Seals near the terminal can use fluororubber with high hardness and excellent oil resistance, specifically designed for static pressure sealing of high-temperature, high-pressure oil inside the gearbox. Seals B near the wire side can use silicone or thermoplastic elastomers with better resilience and lower friction coefficient, specifically responsible for the dynamic following and dust and water protection of the wire harness. When multiple seals are arranged longitudinally in series along the axis, a closed "retention cavity" is formed between them. If the first inner seal experiences a slight leak, the leaked oil will be retained in the cavity between the two seals instead of leaking directly into the external environment. This retention cavity acts as a pressure buffer and secondary sealing mechanism. By breaking down complex monolithic seals into multiple simple units, horizontal parallel arrangement allows for the use of seals with different inner diameters for different terminal specifications (such as thick power lines vs. thin signal lines), without sacrificing the overall seal performance for a few special terminals. Vertical series connection allows for the installation of terminals and wires first, followed by sequentially inserting the seals one by one, reducing the assembly difficulty and damage risk of large monolithic seals, lowering the skill requirements for assembly workers, reducing seal failures caused by improper assembly, and facilitating the individual replacement of damaged seal units during after-sales maintenance. A single thick-walled seal, under pressure, exhibits uneven internal stress distribution, making it prone to permanent deformation. Multiple thin-walled seals connected in series distribute compressive deformation across multiple contact surfaces, resulting in each seal experiencing less compression and more sufficient rebound, significantly extending the seal's fatigue life and long-term reliability over a wide temperature range.

[0012] As a further improved technical solution, the seal is provided with several holes. These holes, for example, are hollow grooves or multi-layered lip structures, which can release stress and act as a pressure equalization layer. They utilize the compressibility of gas to absorb vibration. At the same time, when the internal pressure increases, the holes will further open and tighten against the wire, achieving a self-reinforcing effect of the seal becoming tighter with higher pressure. In addition, the holes also have a shock-absorbing and buffering function, keeping the connection performance between the terminal and the connector stable.

[0013] As a further improved technical solution, the connector has a socket, the diameter of which is no larger than the outer diameter of the seal. The outer diameter of the seal is usually designed to be slightly larger than the diameter of the socket. During installation, the seal is compressed and undergoes elastic deformation, thereby generating high contact pressure at the contact interface, filling all microscopic gaps, and achieving a seal. Specifically, the seal exerts radial compression on the socket, that is, after the seal is inserted into the socket, it expands and presses outward, cutting off the leakage path along the hole wall.

[0014] As a further improved technical solution, the outer diameter of the wire is not less than the inner diameter of the seal, and the seal is fitted onto the wire. This causes the seal to radially compress the wire. When the wire passes through the seal, it is tightly wrapped by the seal, and the seal material flows along the spiral grooves on the wire surface, creating a labyrinth effect. Because the outer diameter of the wire is slightly larger than the inner diameter of the seal (interference fit), at the moment of insertion, the seal material is forced to flow along the grooves of the spiral grooves of the wire. This forced shear flow forces the rubber material to embed into the microscopic grooves of the spiral grooves, forming countless tiny "mechanical interlocking points," rather than simply relying on elasticity. With a normal smooth wire passing through the seal, the leakage path is straight. However, after the spiral grooves guide the flow of the sealing material, the resulting sealing interface is three-dimensionally spiral. For the medium to leak, it must overcome surface tension and material resistance along this meandering path, causing the leakage resistance to increase exponentially. The presence of the spiral grooves results in uneven radial compression of the seal. The compression is large at the peaks of the grooves (where the outer diameter of the wire is largest) and small at the valleys (where the outer diameter of the wire is smaller). This uneven compression can better absorb material creep and compression set during long-term use, maintaining continuous contact pressure.

[0015] As a further improved technical solution, the sealing element includes a first protrusion and a second protrusion. The first protrusion is close to the terminal, and the second protrusion is located on the side of the first protrusion away from the terminal. The first protrusion is configured to correspond one-to-one with the terminal, and the second protrusion is sleeved on multiple wires. The first protrusion achieves individual sealing of the terminal, and the second protrusion achieves collective sealing of the wire harness. The first and second protrusions work together to create at least two continuous sealing barriers of different principles in the leakage path, achieving double sealing protection in the direction of the wires. Even if the seal at a certain terminal fails in extreme cases, the leakage will be limited to the independent cavity where the terminal is located and will not affect the electrical connection of other terminals. The first and second protrusions are integrally formed elastic sealing elements, integrating multiple independent sealing points into a whole, eliminating problems such as twisting and misalignment that may occur when assembling multiple sealing elements, reducing assembly time, improving sealing pressure consistency, and significantly improving production yield and product reliability.

[0016] As a further improved technical solution, the sealing element is made of at least one of silicone, fluororubber, fluorosilicone rubber, hydrogenated nitrile rubber, EPDM rubber, and thermoplastic elastomer. The sealing element has a certain degree of elasticity, allowing it to adapt to the contact surfaces of wires and connectors, achieving superior sealing performance. Vehicle vibration energy can be effectively absorbed and attenuated by the sealing element material, preventing wire harness wear and terminal detachment caused by vibration, thus greatly improving safety.

[0017] As a further improved technical solution, the conductor is fitted with a sheath, the material of which includes at least one of Teflon, perfluoroalkoxy, fluorinated ethylene propylene, ethylene-tetrafluoroethylene copolymer, silicone rubber, and glass fiber. This sheath effectively protects the conductor from oil and moisture in the gearbox. This application can provide at least one radially protruding limiting rib on the outer circumferential surface of the sheath, and a limiting groove adapted to the limiting rib is formed on the inner circumferential surface of the aforementioned second protrusion. When the second protrusion is fitted onto the conductor, the limiting rib engages with the limiting groove, forming a circumferential locking structure. This solution, through physical fitting, completely locks the relative position of the sheath and the seal, ensuring long-term sealing stability with "zero slippage." The cooperation between the rib and the groove naturally provides guidance and centering, preventing seal distortion during assembly, reducing worker operation difficulty, improving assembly consistency and yield rate. The engaging action causes controllable plastic deformation of the seal material, generating higher radial clamping force at the contact interface, improving high-pressure resistance.

[0018] As a further improved technical solution, the material of the sheath in this application can be polytetrafluoroethylene (PTFE) or modified PTFE, and the material of the second protrusion is fluororubber. The outer surface of the sheath is subjected to plasma surface activation treatment, so that its surface tension is between that of PTFE and fluororubber, in order to promote the wetting and bonding of the second sealing part on the outer surface of the sheath. This solution, through surface activation treatment, greatly improves the interfacial compatibility between rubber and sheath without destroying the oil resistance of PTFE itself, and achieves a tight bond at the "molecular level". It retains the inherent low friction characteristics of PTFE sheath, so that the wire harness can easily pass through the narrow housing hole during cylinder assembly without the seal being flipped or sheared due to excessive friction. PTFE material itself has an extremely low permeability to media such as transmission oil and fuel. As the first barrier, it can effectively prevent the media from penetrating through the wire insulation layer itself.

[0019] As a further improved technical solution, the axial length of the sheath in this application extends to cover the end face of the second protrusion away from the terminal; the end of the sheath and the outer wall of the connector housing together clamp and compress the end of the second protrusion to form an axial end face seal. This solution utilizes the rigidity (or semi-rigidity) and length of the sheath to transmit the pressure of the outer housing or clamp to the end of the seal, forming an additional axial end face seal. This effectively blocks the capillary permeation path of the medium along the junction of the "wire-seal-housing"; the sheath extends and clamps the seal, which can effectively absorb and disperse the stress generated on the crimping point when the wire is bent, preventing the wire from breaking at the root due to repeated bending, while protecting the integrity of the sealing interface; the extended part of the sheath covers the weak edge of the seal like a "sleeve", preventing external dust and sand from directly contacting and abrading the surface of the seal, thus improving weather resistance.

[0020] This invention discloses a hybrid vehicle transmission through-cylinder wiring harness designed for high sealing requirements. Through a unique triple-seal design of radial sealing, end sealing, and surface sealing, it effectively blocks media intrusion from multiple dimensions. The seals can adaptively deform with temperature / pressure changes, maintaining sealing pressure at all times. Through this structural design and material adaptation, this hybrid vehicle transmission through-cylinder wiring harness achieves high sealing performance, high reliability, and resistance to harsh environments, meeting the stringent requirements for transmission through-cylinder wiring harnesses. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the overall structure of the through-cylinder wiring harness for a hybrid vehicle transmission based on high sealing requirements, as described in this application.

[0022] Figure 2 This is a planar schematic diagram and an AA cross-sectional view of the 18-pin connector of this application.

[0023] Figure 3 This is a planar schematic diagram and a BB cross-sectional view of the resolver sensor according to an embodiment of this application.

[0024] Figure label: 1. Pin connector; 2. Resolver sensor connector; 3. Solenoid valve sensor connector; 4. Gearbox cylinder sensor connector; 5. Wire; 6. Cable tie; 11. Housing body; 12. Sealing bushing; 13. End face seal; 14. First mounting flange; 15. 18PIN connector housing; 16. First terminal; 17. Auxiliary fixing component; 18. Reinforcing rib; 19. Positioning groove; 21. Main body and object body; 22. Seal; 23. Locking buckle; 24. Second terminal; 25. Auxiliary seal; 26. Second mounting flange; 27. Reinforcing rib; 28. Bottom sealing surface. Detailed Implementation

[0025] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, the accompanying drawings show only the parts relevant to the present invention, and not all of the structures.

[0026] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "set up," "connection," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0027] Reference Figure 1 This embodiment of a hybrid vehicle transmission cylinder wiring harness based on high sealing requirements includes a pin connector 1, a resolver sensor connector 2, a solenoid valve sensor connector 3, a transmission cylinder sensor connector 4, a wire 5, and a cable tie 6. Terminals are crimped to both ends of the wire 5, and the terminals are crimped securely at both ends of the wire. Electrical connections are formed by inserting the terminals into the above-mentioned connectors. A sealing element is provided on the side of the wire near the terminal, and the terminal is located between the sealing element and the connector.

[0028] Example 1 The pin connector in this embodiment is an 18-pin connector, and its cross-sectional view is shown below. Figure 2 As shown. A sealing bushing 12 and an end face seal 13 are fitted on the side of the wire near the first terminal 16. The outer side of the sealing ring has a serrated protrusion, and the end face seal 13 has a hole.

[0029] The installation process of the 18-pin connector in the through-cylinder wiring harness of a hybrid vehicle transmission based on high sealing requirements in this application embodiment includes the following steps: Step S11: Pre-installation of seals; Radial sealing bushing 12 assembly: The radial sealing bushing 12 made of fluororubber / silicone rubber is fitted into the rod of the first terminal 16 to ensure that the bushing and the terminal are interference fit, with an interference of 0.1~0.3mm, without twisting or air bubbles, and the coaxiality can be ensured by tooling positioning.

[0030] Assembly of end face seal 13: Attach the thin rubber seal to the bottom of the first terminal 16 or match the corresponding groove in the inner cavity of the housing to ensure that the seal covers the gap area between the terminal and the housing. It can be fixed by dispensing glue or pre-pressing fixtures.

[0031] Step S12: Pre-assembly of terminals, seals, and housing; The first terminal 16, with radial sealing bushing 12 and end face seal 13, is inserted into the terminal cavity of the housing body 11: the terminal slides in along the positioning groove 19 to ensure that the terminal is coaxial with the cavity; the radial sealing bushing 12 is compressed by the housing cavity to form an initial radial seal; the end face seal 13 contacts the bottom surface of the inner cavity of the housing to form an end face seal; the locking buckle is engaged in the terminal slot to prevent the terminal from coming out.

[0032] Step S13: Wire harness crimping and assembly integration; After stripping and tinning the wires of the gearbox wiring harness, insert them into the crimping area of ​​the first terminal 16 and cold-press them with a crimping tool. The crimping height and width meet the process requirements to ensure reliable electrical connection between the wires and the terminal. The tensile force is not less than 60N and the wires can withstand temperatures above 150℃.

[0033] Step S14: Install the cylinder into the gearbox housing.

[0034] Clean the gearbox housing mounting holes: Use a lint-free cloth and a special cleaning agent (such as alcohol) to remove oil and metal filings, ensuring the hole walls are dry and undamaged; Alignment and installation: Align the connector, including terminals, seals, and housing, with the gearbox housing mounting holes, ensuring the sealing lip of the first mounting flange 14 faces the outside of the gearbox; Screw / press-in installation: Use a torque wrench to screw / press the connector into the mounting holes, with a torque not exceeding 5 N·m to avoid housing deformation, until the first mounting flange 14 is flush with the end face of the gearbox housing, and the sealing lip is compressed by 0.2~0.5 mm, forming a surface seal; Check the seal: After installation, test by blowing compressed air in reverse or immersing in oil to check for leaks in the terminal holes and flange faces.

[0035] The working principle of the technical solution in this application includes radial sealing, end face sealing, surface sealing, and mechanical locking. The radial sealing bushing 12 is interference-fitted with the first terminal 16 and is simultaneously compressed by the housing cavity, filling the radial gap between the terminal and the housing, preventing transmission oil and water vapor from seeping in / out from the cylinder direction. The end face seal 13 fills the gap between the bottom of the first terminal 16 and the inner cavity of the housing body 11, preventing the medium from intruding from the terminal's tail pressing area side, forming a "bidirectional" seal. The sealing lip of the first mounting flange 14 is interference-fitted with the wall of the transmission housing mounting hole, i.e., a compression seal, forming an external surface seal, blocking external water and dust from entering. The snap-fit ​​structure between the terminal and the housing, and the positioning groove 19, limit terminal displacement, ensuring continuous pressure on the seal and preventing vibration from causing seal failure.

[0036] The hybrid vehicle transmission cylinder-penetrating wiring harness technology solution based on high sealing requirements in this application embodiment can bring the following beneficial effects: (1) High sealing performance, adaptable to the harsh environment of the gearbox: The gearbox is subject to high temperature of 120℃~150℃, high oil pressure, strong vibration during shifting, and corrosion of ATF oil. The triple structure of radial, end face and surface sealing makes the connector IP67 / IP6K9K level sealing. It can be immersed in 1 meter of water for 30 minutes without leakage, effectively preventing oil leakage from causing short circuits and corrosion, or water vapor from causing terminal oxidation.

[0037] (2) Electrical connection reliability: The independent structure of the terminal crimping area is cold-pressed to the wire, with a contact resistance of ≤5mΩ and a temperature resistance of ≥150℃; the locking buckle and positioning groove limit the displacement of the terminal, and the contact resistance changes by ≤10% under vibration conditions such as gear shifting impact, frequency 10~500Hz, and acceleration 20g, to avoid signal interruption and current loss.

[0038] (3) Mechanical strength and durability: The reinforcing ribs 18 of the outer shell body 11 and the thick-walled design of the first mounting flange 14 make the connector resistant to impact and undamaged under 50J impact energy. It also makes the connector resistant to vibration and undamaged under 2000 hours of vibration test. The seals are made of fluororubber, which is oil-resistant and temperature-resistant, with a temperature range of -40℃ to 150℃ and a service life of not less than 15 years / 200,000 kilometers.

[0039] (4) Easy installation: The pre-assembled seals, terminals and housings only need to be aligned with the mounting holes and pressed in on site. The installation time is no more than 5 minutes per unit. The torque is controllable to avoid cracking of the housing due to excessive tightness or failure of the seal due to excessive looseness.

[0040] (5) Modular design, compatible with 18PIN wire harness: The 18PIN terminal layout is compact, and the seal is independently adapted to each terminal, compatible with different wire diameters of 0.35~2.5mm², and supports mixed transmission of CAN, sensor signals and motor and solenoid valve power wire harnesses.

[0041] The 18PIN cylinder-through connector in this technical solution achieves "zero leakage, high reliability, and long life" electrical connection through a triple sealing structure of radial sealing, end face sealing, and surface sealing, combined with mechanical locking and environmentally resistant materials, under the harsh operating conditions of high temperature, high pressure, and strong vibration in the gearbox. This solves the industry pain points of poor sealing and easy failure of traditional cylinder-through wiring harnesses.

[0042] Example 2 In this embodiment, the connector in the through-cylinder wiring harness of a hybrid vehicle transmission with high sealing requirements is a resolver sensor connector. The plan view and BB cross-sectional view of this resolver sensor connector are shown below. Figure 3 As shown.

[0043] The installation process of the gearbox through-cylinder resolver sensor connector in this application embodiment includes the following steps: Step S21: Pre-assembly of terminals, seals, and housing assemblies Terminal crimping: After stripping and tinning the wires of the resolver sensor, insert them into the crimping area of ​​the second terminal 24. Use a crimping tool to cold-press the wires to a height of 2-3mm, ensuring full contact between the wires and the metal part of the terminal. The tensile test should be no less than 50N to prevent loosening due to vibration. The second terminal 24 is connected to the wires of the resolver sensor harness through the auxiliary seal 25 in the crimping area, transmitting electrical signals such as angle and speed. The terminal locking buckle 23 ensures that the terminal does not loosen under vibration, guaranteeing signal stability.

[0044] Sealing structure assembly: Fit the fluororubber bushing seal 22 into the second terminal 24, ensuring that the bushing and the terminal are interference fit with an interference of 0.1-0.2mm, without wrinkles or twisting; then place the silicone pad auxiliary seal 25 at the bottom of the second terminal 24 on the contact surface with the main housing 21.

[0045] Terminal insertion into the housing: Insert the second terminal 24 with the seal into the terminal cavity of the main housing 21, so that the terminal locking buckle 23 snaps into the slot of the main housing. After hearing a "click", gently pull the terminal to confirm that it has not come out. The reinforcing ribs 27 of the main housing 21 increase strength and prevent deformation; the bottom sealing surface 28 disperses the installation pressure and ensures sealing stability.

[0046] Step 22: Wire harness arrangement and housing closure: Insert the wire harness with crimped terminals into the upper cavity of the main housing 21, and arrange the wire harness to avoid crossing or squeezing; install the housing cover, ensuring that the cover and the main housing 21 are engaged by the snap / screw, and that the seal 22 is not displaced within the main housing.

[0047] Step 23: Install to gearbox housing: Clean the mounting holes of the gearbox housing to remove oil and metal filings, and align the connector containing the wiring harness with the mounting holes; with the sealing lip of the second mounting flange 26 facing the outside of the gearbox housing, use a torque wrench to press the connector into the mounting hole until the second mounting flange 26 fits against the end face of the gearbox housing and the sealing lip is compressed.

[0048] The sealing principle of the technical solution in this embodiment includes radial sealing, end face sealing, and surface sealing.

[0049] The fluororubber bushing seal 22 is interference-fitted with the second terminal 24 to fill the gap between the terminal and the housing cavity, preventing gearbox oil and water vapor from radially seeping in from the terminal hole; the silicone gasket auxiliary seal 25 fills the gap between the bottom of the terminal and the inner cavity of the housing, preventing the medium from entering from the crimping area side; the sealing lip of the second mounting flange 26 is in close contact with the wall of the gearbox housing hole to form a surface seal, blocking external medium from entering the connector.

[0050] The hybrid vehicle transmission cylinder-penetrating wiring harness technology solution based on high sealing requirements in this application embodiment can bring the following beneficial effects: (1) High sealing performance: The radial, end face and surface triple sealing design can withstand the transmission oil temperature and oil pressure, and prevent oil and water vapor from entering for a long time, avoiding short circuits and signal distortion.

[0051] (2) Vibration / shock resistance: In this embodiment, the terminal locking buckle 23 and the interference seal 22 do not loosen or fail under strong vibration of the gearbox, ensuring reliable signal transmission.

[0052] (3) Environmental resistance: The combination of fluororubber seal 22, silicone auxiliary seal 25 and high temperature resistant nylon 21 is resistant to gearbox oil, high temperature and aging, and has a service life of not less than 10 years.

[0053] (4) Easy to install / maintain: The positioning design of the second mounting flange 26 and the torque controllable installation method reduce the assembly difficulty; the pre-assembled sealing structure reduces the on-site debugging time.

[0054] (5) Stable signal: The copper alloy second terminal 24 is precisely crimped with a contact resistance of no more than 5mΩ, ensuring that the angle and speed signals of the resolver sensor are not attenuated or interfered with.

[0055] Through the synergy of the above structural design, installation process, and working principle, this connector achieves the core advantages of high sealing, vibration resistance, environmental resistance, and stable signal, perfectly adapting to the harsh working conditions of gearbox cylinder wiring harnesses.

[0056] Furthermore, the above embodiments are only used to illustrate the present invention and are not intended to limit the technical solutions described in the present invention. The understanding of this specification should be based on those skilled in the art. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that they can still make modifications or equivalent substitutions to the present invention. All technical solutions and improvements that do not depart from the spirit and scope of the present invention should be covered within the scope of the claims of the present invention.

Claims

1. A hybrid vehicle transmission cylinder-penetrating wiring harness based on high sealing requirements, characterized in that: The device includes a wire and a connector. The wire has terminals crimped to both ends and is inserted into the connector through the terminals to form an electrical connection. The wire has a seal on the side near the terminal, and the terminal is located between the seal and the connector.

2. The hybrid vehicle transmission cylinder wiring harness based on high sealing requirements according to claim 1, characterized in that: The connectors include pin connectors and / or resolver sensor connectors.

3. The hybrid vehicle transmission cylinder wiring harness based on high sealing requirements according to claim 1, characterized in that: The connector also includes a gearbox in-cylinder sensor connector and / or a solenoid valve sensor connector.

4. The hybrid vehicle transmission cylinder wiring harness based on high sealing requirements according to claim 1, characterized in that: The seal includes a plurality of protrusions, which are at least one of a wavy shape, a zigzag shape, or an arc shape.

5. The hybrid vehicle transmission cylinder wiring harness based on high sealing requirements according to claim 4, characterized in that: The sealing element has several holes.

6. The hybrid vehicle transmission cylinder-penetrating wiring harness based on high sealing requirements according to claim 1, characterized in that: The connector has a socket, the diameter of which is not greater than the outer diameter of the seal.

7. The hybrid vehicle transmission cylinder wiring harness based on high sealing requirements according to claim 1, characterized in that: The sealing element includes a first protrusion and a second protrusion. The first protrusion is close to the terminal, and the second protrusion is located on the side of the first protrusion away from the terminal. The first protrusion is provided in a one-to-one correspondence with the terminal, and the second protrusion is sleeved on multiple wires.

8. The hybrid vehicle transmission cylinder wiring harness based on high sealing requirements according to claim 7, characterized in that: The conductor is fitted with a sheath, the axial length of which extends to cover the end face of the second protrusion away from the terminal; the end of the sheath and the outer wall of the connector housing together clamp and compress the end of the second protrusion to form an axial end face seal.

9. The hybrid vehicle transmission cylinder wiring harness based on high sealing requirements according to claim 1, characterized in that: The material of the seal includes at least one of silicone, fluororubber, fluorosilicone rubber, hydrogenated nitrile rubber, EPDM rubber, and thermoplastic elastomer.

10. The hybrid vehicle transmission cylinder wiring harness based on high sealing requirements according to claim 1, characterized in that: The conductor is fitted with a sheath, the material of which includes at least one of Teflon, polytetrafluoroethylene, modified polytetrafluoroethylene, perfluoroalkoxy, fluorinated ethylene propylene, ethylene-tetrafluoroethylene copolymer, silicone rubber, and glass fiber.

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