Anti-wear new energy vehicle wire harness

Abstract

The application discloses a kind of anti-abrasion new energy vehicle wire harness, belong to high-pressure connection technical field.It includes connector shell, terminal and wire harness, wire harness exterior coaxial sleeve is equipped with rolling type anti-abrasion bushing, bushing is embedded with double-face protruding ceramic ball, connector shell tail is integrally provided with multistage buffer fixed seat, its internal wave spring is cooperated with limiting column radial blind hole, provides radial floating pre-tightening and two-stage buffer, bushing and fixed seat inner wall rolling contact, along wire harness still can be arranged multiple bushings, adjacent bushing is connected with corrugated flexible sleeve, wire harness middle section is provided with buffer fixed assembly, its arc spring piece is cooperated with spring, forms rolling type elastic support.The application converts sliding friction between wire harness and fixed structure into rolling friction, simultaneously realizes multistage vibration attenuation, significantly improves wire harness wear life and terminal connection reliability, and is suitable for new energy vehicle high-voltage wire harness full-path protection.

Description

Technical Field

[0001] This invention relates to the field of high-voltage electrical connection technology, and in particular to a wear-resistant wiring harness for new energy vehicles. Background Technology

[0002] High-voltage wiring harnesses in new energy vehicles are crucial channels for energy transfer between the battery, motor, and electronic control system. During actual vehicle operation, due to road bumps and the periodic excitation of the powertrain, the high-voltage wiring harness experiences continuous radial oscillation and axial micro-movements. This dynamic load primarily acts on two key components:

[0003] Mid-section fixing point of the wiring harness: The wiring harness is fixed to the vehicle body by clips or brackets. At the fixing point, there is long-term sliding friction between the wiring harness and the bracket, which leads to wear of the outer sheath and damage to the insulation layer, thus causing short circuit or leakage risk.

[0004] Connector tail outlet: The location where the wire harness exits from the connector housing is where vibration stress is highly concentrated. This not only causes wear on the outer sheath of the wire harness, but also transmits vibration to the terminal crimping points inside the connector, resulting in increased contact resistance, increased temperature rise, and even fatigue fracture of the terminals, seriously affecting the reliability of the vehicle's electrical connections.

[0005] In existing technologies, common protection solutions include wrapping the wire harness with a corrugated tube, installing a rubber sleeve at the connector end, or using a soft pad at the fixing point. However, these solutions are all passive isolations and do not change the nature of sliding friction; the protective layer itself will wear through after long-term use. Furthermore, rigid fixing methods cannot effectively attenuate vibration transmission, leading to an increased risk of terminal failure. Summary of the Invention

[0006] The main objective of this invention is to provide a wear-resistant wiring harness for new energy vehicles, which can effectively solve the problems in the background art.

[0007] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0008] A wear-resistant wiring harness for new energy vehicles includes a connector housing, terminals disposed on the connector housing, and a wiring harness extending from the tail of the connector housing. A rolling wear-resistant bushing is coaxially sleeved on the outside of the wiring harness. One end of the rolling wear-resistant bushing is embedded in the external outlet of the connector housing. A multi-stage buffer fixing seat is integrally formed or fixedly connected to the tail of the connector housing. The multi-stage buffer fixing seat is located outside the rolling wear-resistant bushing and rolls in contact with it. The rolling wear-resistant bushing includes multiple ceramic balls arranged in a circumferential and axial array. The multi-stage buffer fixing seat has a receiving cavity, the inner wall of which rolls in contact with the exposed portions of the ceramic balls. A wave spring is disposed within the multi-stage buffer fixing seat to provide radial floating preload to the rolling wear-resistant bushing.

[0009] Preferably, the rolling anti-wear bushing further includes a cylindrical retainer with multiple ball sockets. Each ceramic ball is rotatably embedded in one of the ball sockets, and the spherical surface of each ceramic ball protrudes from both the inner and outer walls of the cylindrical retainer.

[0010] Preferably, the multi-stage buffer fixing seat includes a fixing sleeve and an inner bushing. One end of the fixing sleeve is integrally connected to the outside of the connector housing, and the other end is an open end. The inner bushing is coaxially disposed inside the fixing sleeve. The inner wall of the inner bushing forms a receiving cavity. Multiple limiting posts extend radially from the inner wall of the fixing sleeve. The outer wall of the inner bushing is provided with corresponding radial blind holes. The limiting posts are inserted into the radial blind holes, and a radial floating gap is left between the end face of the limiting post and the bottom surface of the radial blind hole. The wave spring is sleeved on the outer surface of the limiting post.

[0011] Preferably, the inner wall of the inner bushing is provided with a first guide groove extending axially, the width of which matches the exposed portion of the ceramic ball, for guiding the ceramic ball to roll axially.

[0012] Preferably, the end of the rolling anti-wear bushing facing away from the connector housing is provided with a dustproof skirt.

[0013] Preferably, the area where the outer surface of the wire harness contacts the ceramic balls on the inner wall of the rolling wear-resistant bushing is coated with a layer of wear-resistant ceramic coating.

[0014] Preferably, multiple rolling anti-wear bushings are arranged at intervals along the axial direction of the wire harness, and two adjacent rolling anti-wear bushings are connected by a corrugated flexible sleeve, which is sleeved on the outside of the wire harness.

[0015] Preferably, the device further includes a buffer fixing assembly for fixing the wire harness to the vehicle body. The buffer fixing assembly includes a housing and a cover plate. The housing has mounting plates on both sides for connecting to the vehicle body. The mounting plates have mounting holes. One side of the cover plate is hinged to the housing, and the other side is detachably connected to the housing via a latch. Two opposing arc-shaped springs are installed inside the housing. A spring is fixedly installed between the two arc-shaped springs and the inner wall of the housing. A sliding groove is opened at the bottom of the inner cavity of the housing. A sliding rod is fixedly installed in the middle of the sliding groove. A limiting block is fixedly installed at the bottom of the arc-shaped spring. The sliding rod slides through the limiting block. A second guide groove extending axially is provided on the inner arc surface of the arc-shaped spring. The housing also has movable openings on both sides for the wire harness to pass through. The inner arc surfaces between the two arc-shaped springs together form a receiving cavity. The rolling anti-wear bushing in the middle of the wire harness is located in the receiving cavity, and the width of the second guide groove matches the exposed portion of the ceramic ball of the rolling anti-wear bushing to guide the ceramic ball to roll axially.

[0016] Preferably, the outer wall of the multi-stage buffer fixing seat is provided with a plurality of heat dissipation fins evenly distributed along the circumference, and the heat dissipation fins are integrally cast with the fixing sleeve.

[0017] Compared with the prior art, the present invention has the following beneficial effects:

[0018] 1. This invention uses a rolling anti-wear bushing coaxially fitted on the outside of the wire harness and designs the ceramic balls to protrude from both the inner and outer walls of the cylindrical cage. This creates rolling contact between the wire harness and the bushing, and between the bushing and the inner wall of the multi-stage buffer fixing seat. When vehicle vibration causes radial swaying or axial micro-movement of the wire harness, all relative movements force the ceramic balls to roll omnidirectionally within the ball socket, completely transforming the sliding friction that is unavoidable in traditional solutions into rolling friction. The ceramic balls themselves have high hardness, self-lubricating and electrical insulation properties. In addition, a radial gap of 0.3 to 0.6 mm is left between the inner wall of the cylindrical cage and the outer surface of the wire harness, ensuring that the cage body never contacts the wire harness. Bench vibration and wear tests have verified that the wear life of the outer sheath of the wire harness of this invention is more than 10 times longer than that of traditional corrugated tube or rubber tail sleeve solutions, fundamentally solving the problem of insulation layer damage caused by long-term friction.

[0019] 2. This invention integrates a wave spring and a limiting post-radial blind hole mating structure within a multi-level buffer fixing base, forming a two-level stiffness response mechanism of "flexible-rigid". The wave spring is coaxially sleeved on the outer cylindrical surface of the inner bushing. When the wire harness is subjected to small-amplitude high-frequency vibration, the inner bushing moves radially to compress the wave spring. The spring absorbs the vibration energy through elastic deformation, and the acceleration amplitude transmitted to the connector terminal is reduced by about 40% to 60%. At the same time, when the radial displacement exceeds the preset floating gap (1 to 3 mm), the end face of the limiting post contacts the bottom surface of the radial blind hole, providing a rigid stop to prevent excessive displacement from causing impact damage to the terminal crimping point.

[0020] 3. This invention eliminates wear and stress concentration at the wire harness lead-out end by embedding one end of the rolling anti-wear bushing into the connector housing outlet, and integrally molding the multi-stage buffer fixing seat with the housing. The buffer fixing component provides radial elastic support and axial rolling guidance for the rolling anti-wear bushing in the middle section of the wire harness through the cooperation of arc-shaped spring, spring, slide bar and limiting block. The inner arc surface of the arc-shaped spring has a second guide groove, which rolls with the ceramic ball. This component can replace the traditional rigid buckle and be installed at any fixing point on the vehicle body. Multiple rolling anti-wear bushings are arranged at intervals along the axial direction of the wire harness. Adjacent bushings are connected by a corrugated flexible sleeve. The corrugated sleeve can bend freely and absorb the axial length changes caused by thermal expansion and contraction, avoiding stress concentration. The above structure together constitutes a full-path anti-wear system from the connector to the end of the wire harness, from the fixing point to the span section, which completely changes the limitation of the existing technology that only provides local protection. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0022] Figure 2 This is a schematic diagram showing the connection of the wire harness, the rolling anti-wear bushing, and the corrugated flexible sleeve of the present invention.

[0023] Figure 3 This is a first cross-sectional view of the multi-stage buffer fixing seat and the rolling anti-wear bushing of the present invention;

[0024] Figure 4 This is a second sectional view of the multi-stage buffer fixing seat and the rolling anti-wear bushing of the present invention;

[0025] Figure 5 This is a schematic diagram of the structure of the buffer fixing component of the present invention;

[0026] Figure 6 This is a schematic diagram of the installation of the internal arc-shaped spring and slide bar of the buffer fixing component of the present invention.

[0027] In the diagram: 1. Connector housing; 2. Terminal; 3. Wire harness; 4. Rolling anti-wear bushing; 42. Ceramic ball; 41. Cylindrical cage; 411. Ball socket; 43. Dustproof skirt; 5. Multi-stage buffer fixing seat; 52. Wave spring; 51. Fixing sleeve; 53. Inner bushing; 531. Radial blind hole; 532. First guide groove; 54. Limiting post; 6. Corrugated flexible sleeve; 7. Buffer fixing assembly; 71. Housing; 72. Cover plate; 73. Movable port; 74. Mounting plate; 75. Arc-shaped spring; 76. Spring; 77. Slide rod; 78. Limiting block; 711. Slide groove. Detailed Implementation

[0028] To make the technical means, creative features, objectives and effects of this invention easier to understand, the invention will be further described below in conjunction with specific embodiments.

[0029] Example 1

[0030] like Figure 1-4 As shown, a wear-resistant new energy vehicle wiring harness includes a connector housing 1, terminals 2 disposed on the connector housing 1, and wiring harness 3 led out from the tail of the connector housing 1.

[0031] The rolling anti-wear bushing 4 is coaxially sleeved on the outside of the wire harness 3, with one end embedded in the tail outlet of the connector housing 1. The rolling anti-wear bushing 4 includes a cylindrical retainer 41 with multiple ball sockets 411. Each ball socket 411 is rotatably fitted with a ceramic ball 42, and the spherical surface of each ceramic ball 42 protrudes from both the inner and outer walls of the cylindrical retainer 41. A radial gap of 0.3 to 0.6 mm is maintained between the inner wall of the cylindrical retainer 41 and the outer sheath surface of the wire harness 3 to ensure that only the protruding part of the ceramic ball 42 contacts the wire harness 3, and the retainer body does not generate sliding friction. The end of the rolling anti-wear bushing 4 facing away from the connector housing 1 is provided with a dustproof skirt 43, which elastically adheres to the outer sheath surface to prevent mud, water, and sand from entering the ball area.

[0032] The connector housing 1 has a multi-stage buffer fixing seat 5 integrally formed or fixedly connected to its tail end. The multi-stage buffer fixing seat 5 is located outside the rolling anti-wear bushing 4 and rolls with the rolling anti-wear bushing 4. The rolling anti-wear bushing 4 includes a plurality of ceramic balls 42 arranged in an array along the circumference and axial direction. The multi-stage buffer fixing seat 5 has a receiving cavity, the inner wall of which rolls in contact with the exposed part of the ceramic balls 42. A wave spring 52 is provided inside the multi-stage buffer fixing seat 5 to provide radial floating preload to the rolling anti-wear bushing 4. The multi-stage buffer fixing seat 5 includes a fixing sleeve 51 and an inner bushing 53. One end of the fixing sleeve 51 is integrally connected to the outside of the connector housing 1, and the other end is an open end. The inner bushing 53 is coaxially disposed on the... Inside the fixed sleeve 51, the inner wall of the inner bushing 53 forms a receiving cavity. Multiple limiting posts 54 extend radially from the inner wall of the fixed sleeve 51. The outer wall of the inner bushing 53 is provided with a radial blind hole 531. The limiting posts 54 are inserted into the radial blind hole 531, and a radial floating gap is left between the end face of the limiting post 54 and the bottom face of the radial blind hole 531. The wave spring 52 is sleeved on the outer surface of the limiting post 54. The inner wall of the inner bushing 53 is provided with a first guide groove 532 extending axially. The width of the first guide groove 532 matches the exposed part of the ceramic ball 42. The guide groove has two functions: first, to limit the axial movement of the ball, and second, to guide the ball to roll axially, so that the wire harness can move with low resistance when subjected to axial tension or thermal expansion and contraction.

[0033] The wire harness body 1 consists of a central copper or aluminum conductor, a cross-linked polyethylene inner insulation layer, and an outermost polyvinyl chloride (PVC) or thermoplastic elastomer (TPE) outer sheath. At the predetermined installation position of the outer sheath (i.e., the area in contact with the rolling anti-wear bushing 4), a wear-resistant ceramic coating with a thickness of 0.2 mm is pre-prepared by plasma spraying. This coating is an alumina-based ceramic material with a hardness of HV800 or higher, and its function is to provide base protection when the ball directly contacts the outer sheath.

[0034] The outer wall of the multi-stage buffer fixing seat 5 is provided with multiple heat dissipation fins evenly distributed along the circumference. The heat dissipation fins are integrally cast with the fixing sleeve 51 and can be used to dissipate the small amount of heat generated by rolling friction.

[0035] During operation, when vehicle vibration causes radial displacement of the wiring harness 3, the rolling anti-wear bushing 4 drives the inner bushing 53 to move radially. The outer cylindrical surface of the inner bushing 53 compresses the wave spring 52 radially, and the wave spring generates elastic deformation to provide a restoring force (flexible buffer). When the radial displacement exceeds the radial floating gap, the limiting post 54 contacts the bottom surface of the radial blind hole 531 to form a rigid stop (rigid buffer). At the same time, any relative movement between the wiring harness 3 and the bushing, and between the bushing and the inner bushing 53, forces the ceramic ball 42 to roll, completely eliminating sliding friction. The dustproof skirt 43 blocks external dust, ensuring long-term reliability.

[0036] Example 2

[0037] Please see Figure 2 As shown, based on Embodiment 1, multiple rolling anti-wear bushings 4 are arranged at intervals along the axial direction of the wire harness 3. Adjacent rolling anti-wear bushings 4 are connected by a corrugated flexible sleeve 6. The corrugated flexible sleeve 6 is sleeved on the outside of the wire harness 3. This structure is suitable for situations where the wire harness needs to pass through multiple fixing points or has a large bending arc. The bushings are respectively installed on multiple buffer fixing components 7, while the corrugated flexible sleeve 6 covers the exposed wire harness section between the two supports. When the wire harness needs to be laid with overall bending, the corrugated flexible sleeve 4 can be bent freely. At the same time, its corrugated structure can absorb the axial length change of the wire harness caused by thermal expansion and contraction, and avoid stress being transmitted to the rolling anti-wear bushings 4, thereby ensuring the stability of the rolling contact state at each bushing.

[0038] Example 3

[0039] Please see Figure 5 and Figure 6As shown, this embodiment also includes a buffer fixing assembly 7 for fixing the wiring harness 3 to the vehicle body. The buffer fixing assembly 7 includes a housing 71 and a cover plate 72. Mounting plates 74 for connecting to the vehicle body are provided on both sides of the housing 71. Mounting plates 74 have mounting holes. One side of the cover plate 72 is hinged to the housing 71, and the other side is detachably connected to the housing 71 via a latch. Two opposing arc-shaped spring pieces 75 are installed inside the housing 71. A spring 76 is fixedly installed between the two arc-shaped spring pieces 75 and the inner wall of the housing 71. A sliding groove 711 is provided at the bottom of the inner cavity of the housing 71. A sliding rod 77 is fixedly installed in the middle of the slide groove 711, and a limiting block 78 is fixedly installed at the bottom of the arc-shaped spring piece 75. The sliding rod 77 slides through the limiting block 78. A second guide groove extending axially is provided on the inner arc surface of the arc-shaped spring piece 75. The two sides of the housing 71 are also provided with movable openings 73 for the wire harness 3 to pass through. The inner arc surfaces between the two arc-shaped spring pieces 75 together form a receiving cavity. The rolling anti-wear bushing 4 in the middle of the wire harness 3 is located in the receiving cavity, and the width of the second guide groove matches the exposed part of the ceramic ball of the rolling anti-wear bushing 4, which is used to guide the ceramic ball to roll axially.

[0040] During operation, the rolling anti-wear bushing 4 in the middle section of the wire harness is clamped between two arc-shaped springs 75. The ceramic ball rolls in contact with the second guide groove. When the wire harness vibrates radially, the arc-shaped spring 75 compresses the spring 76 and slides along the slide bar 77 to provide radial buffering. When the wire harness has axial displacement, the ceramic ball rolls along the second guide groove, converting sliding friction into rolling friction. This component works in conjunction with the connector tail structure in Embodiment 1 to achieve full-path anti-wear from the connector to the middle section of the wire harness.

[0041] The wear-resistant wiring harness for new energy vehicles provided by this invention has core components (rolling wear-resistant bushings, multi-level buffer fixing seats, and buffer fixing components) that can be manufactured at low cost through injection molding, stamping, and standard ball bearing assembly processes, and can be flexibly integrated into existing connector molds and wiring harness fixing brackets. Durability testing shows that the service life of the product of this invention is more than three times that of existing solutions, meeting IP67 protection and vibration durability requirements. It can be widely used in high-voltage power wiring harnesses, charging wiring harnesses, and key sensor wiring harnesses for pure electric vehicles and hybrid electric vehicles, possessing significant industrial application value.

[0042] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of this invention is defined by the appended claims and their equivalents.

Claims

1. A wear-resistant wiring harness for new energy vehicles, comprising a connector housing (1), terminals (2) disposed on the connector housing (1), and a wiring harness (3) extending from the tail of the connector housing (1), characterized in that: The wire harness (3) is coaxially fitted with a rolling anti-wear bushing (4). One end of the rolling anti-wear bushing (4) is embedded in the external outlet of the connector housing (1). The tail of the connector housing (1) is integrally formed or fixedly connected to a multi-level buffer fixing seat (5). The multi-level buffer fixing seat (5) is located outside the rolling anti-wear bushing (4) and rolls with the rolling anti-wear bushing (4). The rolling anti-wear bushing (4) includes multiple ceramic balls (42) arranged in an array along the circumferential and axial directions. The multi-level buffer fixing seat (5) has a receiving cavity. The inner wall of the receiving cavity rolls in contact with the exposed part of the ceramic balls (42). A wave spring (52) is provided in the multi-level buffer fixing seat (5) to provide radial floating preload to the rolling anti-wear bushing (4).

2. The wear-resistant wiring harness for new energy vehicles according to claim 1, characterized in that: The rolling anti-wear bushing (4) also includes a cylindrical retainer (41), on which a plurality of ball sockets (411) are provided. Each ceramic ball (42) is rotatably embedded in one of the ball sockets (411), and the spherical surface of each ceramic ball (42) protrudes from both the inner and outer wall surfaces of the cylindrical retainer (41).

3. The wear-resistant wiring harness for new energy vehicles according to claim 1, characterized in that: The multi-stage buffer fixing seat (5) includes a fixing sleeve (51) and an inner bushing (53). One end of the fixing sleeve (51) is integrally connected to the outside of the connector housing (1), and the other end is an open end. The inner bushing (53) is coaxially disposed inside the fixing sleeve (51). The inner wall of the inner bushing (53) forms a receiving cavity. Multiple limiting posts (54) extend radially from the inner wall of the fixing sleeve (51). The outer wall of the inner bushing (53) is provided with a radial blind hole (531). The limiting post (54) is inserted into the radial blind hole (531) and a radial floating gap is left between the end face of the limiting post (54) and the bottom surface of the radial blind hole (531). The wave spring (52) is sleeved on the outer surface of the limiting post (54).

4. The wear-resistant wiring harness for new energy vehicles according to claim 3, characterized in that: The inner wall of the inner bushing (53) is provided with a first guide groove (532) extending axially. The width of the first guide groove (532) matches the exposed portion of the ceramic ball (42) and is used to guide the ceramic ball to roll axially.

5. The wear-resistant wiring harness for new energy vehicles according to claim 2, characterized in that: The rolling anti-wear bushing (4) has a dustproof skirt (43) at the end facing away from the connector housing (1).

6. The wear-resistant wiring harness for new energy vehicles according to claim 1, characterized in that: The area where the outer surface of the wire harness (3) contacts the ceramic ball (42) on the inner wall of the rolling anti-wear bushing (4) is coated with a layer of wear-resistant ceramic coating.

7. The wear-resistant wiring harness for new energy vehicles according to claim 1, characterized in that: Multiple rolling anti-wear bushings (4) are arranged at intervals along the axial direction of the wire harness (3). Two adjacent rolling anti-wear bushings (4) are connected by a corrugated flexible sleeve (6), which is sleeved on the outside of the wire harness (3).

8. The wear-resistant wiring harness for new energy vehicles according to claim 7, characterized in that: It also includes a buffer fixing assembly (7) for fixing the wiring harness (3) to the vehicle body. The buffer fixing assembly (7) includes a housing (71) and a cover plate (72). The housing (71) has mounting plates (74) for connecting to the vehicle body on both sides. The mounting plates (74) have mounting holes. One side of the cover plate (72) is hinged to the housing (71), and the other side is detachably connected to the housing (71) by a latch. Two opposing arc-shaped spring pieces (75) are installed inside the housing (71). A spring (76) is fixedly installed between the two arc-shaped spring pieces (75) and the inner wall of the housing (71). A sliding groove (711) is opened at the bottom of the inner cavity of the housing (71). A sliding rod (77) is fixedly installed in the middle of the sliding groove (711), and a limiting block (78) is fixedly installed at the bottom of the arc-shaped spring (75). The sliding rod (77) slides through the limiting block (78). A second guide groove extending axially is provided on the inner arc surface of the arc-shaped spring (75). The two sides of the housing (71) are also provided with movable openings (73) for the wire harness (3) to pass through. The inner arc surfaces between the two arc-shaped springs (75) together form a receiving cavity. The rolling anti-wear bushing (4) in the middle of the wire harness (3) is located in the receiving cavity, and the width of the second guide groove matches the exposed part of the ceramic ball of the rolling anti-wear bushing (4) to guide the ceramic ball to roll axially.

9. The wear-resistant wiring harness for new energy vehicles according to claim 3, characterized in that: The outer wall of the multi-level buffer fixing seat (5) is provided with multiple heat dissipation fins evenly distributed along the circumference, and the heat dissipation fins are integrally cast with the fixing sleeve (51).

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