A high-voltage wire harness assembly for a new energy vehicle

Abstract

This invention relates to the field of high-voltage electrical connection technology for new energy vehicles, and discloses a high-voltage wiring harness assembly for new energy vehicles. The high-voltage wiring harness assembly includes a second straight section cable on the distribution box side, a first straight section cable on the battery swapping interface side, a connector housing, an inner seat, a floating ring, and a spring terminal block. The connector housing has an internal cavity, in which the inner seat is housed, with a first terminal fixed at its front end. A radial floating gap is reserved between the outer wall of the inner seat and the inner wall of the cavity. The floating ring is fitted around the outer circumference of the inner seat and is inserted into the inner wall of the cavity with an interference fit. This allows the inner seat to undergo radial elastic deformation during blind insertion lateral deviation, enabling it to self-adaptively displace along a plane perpendicular to the axis within the radial floating gap. The spring terminal block is connected between the rear end of the inner seat and the cable conductor of the first straight section cable. It has elastic expansion and contraction capabilities along the axial direction, absorbing blind insertion lateral deviation through the floating ring and buffering axial insertion and extraction impacts with the help of the spring terminal block.

Description

Technical Field

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

[0002] The power battery pack of the battery-swapping new energy commercial vehicle is detachably connected to the vehicle body via a bottom mechanical locking mechanism. During each battery swap, the battery pack rises and falls vertically and blindly plugs into the high-voltage interface on the vehicle body. The high-voltage distribution box on the side of the vehicle body is connected to the battery swapping interface via a high-voltage wiring harness. One end of the wiring harness is fixed to the distribution box, and the other end is inserted into the battery swapping interface connector. Due to the high operating temperature of the commercial vehicle's electric drive system, and the battery swapping interface being located close to the electric drive system, the wiring harness shielding overlap is subjected to temperature cycles ranging from -40 degrees Celsius to 180 degrees Celsius over a long period. At the same time, the blind insertion misalignment and insertion / removal impact force generated during each battery swap cause the terminals to bear a combined load.

[0003] The aforementioned existing technology has the following drawbacks: the connector terminals and housing are rigidly fixed structures without adaptive compensation structures. When there is a lateral misalignment during blind mating, the mating terminals will apply continuous shear stress to the metal terminals at the ends of the wire harness. The stress concentrates at the root of the terminal cable crimp, and after repeated cycles of insertion and removal, metal fatigue cracks are very likely to occur, eventually leading to terminal breakage and high-voltage circuit open circuit faults, which seriously affect the operational reliability of the high-voltage system of the battery swapping vehicle. Summary of the Invention

[0004] This invention provides a high-voltage wiring harness assembly for new energy vehicles, which solves the technical problem that the terminal crimping root is prone to shear fatigue fracture under the mechanical load of blind insertion misalignment and insertion / removal impact in battery-swapping new energy vehicles, leading to terminal breakage and high-voltage circuit open circuit faults.

[0005] This invention discloses a high-voltage wiring harness assembly for new energy vehicles, comprising:

[0006] The first straight section of cable on the battery swapping interface side and the second straight section of cable on the distribution box side are electrically connected;

[0007] The power distribution box connector housing is fixed at the power distribution box interface. A second terminal is crimped inside the power distribution box connector housing. The second terminal is electrically connected to the cable conductor of the second straight section cable.

[0008] The connector housing is fixed at the power swapping interface, and a receiving cavity is provided inside the connector housing;

[0009] An inner seat is accommodated within the receiving cavity. A first terminal is fixed to the front end of the inner seat, and a radial floating gap is reserved between the outer wall of the inner seat and the inner wall of the receiving cavity.

[0010] A floating ring is fitted around the outer periphery of the inner seat. The floating ring is inserted into the inner wall of the receiving cavity with an interference fit. It is used to undergo radial elastic deformation when there is a lateral deviation during blind insertion, so as to allow the inner seat to self-adaptively displace along a plane perpendicular to the axis within the radial floating gap.

[0011] The spring terminal block is connected between the rear end of the inner seat and the cable conductor of the first straight section of the cable, and has elastic expansion and contraction capability along the axial direction.

[0012] Furthermore, the inner wall of the receiving cavity of the connector housing is provided with a stepped groove along the axial direction, and the two ends of the stepped groove in the axial direction have annular stepped surfaces. When the floating ring is installed in the stepped groove, the two end faces of the floating ring in the axial direction respectively fit with the two annular stepped surfaces.

[0013] Furthermore, it also includes a corrugated expansion section, which is located between the second straight section cable and the first straight section cable on the side of the distribution box. The corrugated expansion section includes a conductor bundle, an insulating tube, a shielding flexible tube, and a sheath. The conductor bundle is fitted with an insulating tube, the insulating tube is fitted with a shielding flexible tube, and the shielding flexible tube is covered with a sheath. The two ends of the conductor bundle are electrically connected to the cable conductors of the second straight section cable and the first straight section cable, respectively.

[0014] Furthermore, the strand pitch of the conductor bundle is less than the strand pitch of the cable conductor in the second straight section cable and the strand pitch of the cable conductor in the first straight section cable. The insulating tube is a corrugated insulating tube with equal wall thickness at the crests and troughs. Both ends of the shielding flexible tube are respectively pressed and overlapped with the braided shielding layer of the corresponding straight section cable through pressure rings.

[0015] Furthermore, it also includes a shielding overlap structure disposed on the battery swapping interface side. The shielding overlap structure includes a first connector shielding shell, a first shielding connector, and a first inner liner support ring. The braided shielding layer of the first straight section cable is folded at the end near the connector shell to form a folded section. The folded section is fitted onto the outer wall of the first inner liner support ring. The rear end of the first shielding connector is fitted onto the outer wall of the folded section. The front end of the first shielding connector is inserted into the first connector shielding shell. The first connector shielding shell is fixedly installed on the connector shell.

[0016] Furthermore, the outer wall of the first inner liner support ring is provided with an annular groove along the circumferential direction, the first shielding connector is sleeve-shaped, the front end of the first shielding connector is provided with an insertion section, the outer wall of the insertion section is provided with several axial grooves along the circumferential direction to divide the insertion section into several elastic petals, and the outer wall of each elastic petal is in elastic contact with the inner wall of the first connector shielding shell; the rear end of the first shielding connector is provided with several axial grooves evenly distributed along the circumferential direction to divide the rear end into several elastic claws, each elastic claw is pressed with corrugated pleats along the axial direction, and the corrugated pleats of each elastic claw are bent inward to form a radial flange.

[0017] Furthermore, each elastic claw at the rear end of the first shielding connector is sleeved outside the folded section, and each radial flange is engaged in the annular groove of the outer wall of the first inner liner support ring.

[0018] Furthermore, the first connector shielding shell is flexibly connected to the grounding terminal on the connector housing via a metal strip, and the metal strip is provided with bending allowance to maintain the continuity of the shielded electrical path through bending deformation when the inner seat is radially displaced.

[0019] Furthermore, an insulating sealing sleeve is fitted on the outer end face of the first shielding connector and connector housing, and the insulating sealing sleeve covers the shielding overlap area of ​​the elastic claw and the folded section to the surface of the braided shielding layer of the first straight section cable.

[0020] Furthermore, it also includes a shielding overlap structure disposed on the side of the distribution box. The shielding overlap structure on the side of the distribution box includes a second connector shielding shell, a second shielding connector, and a second inner liner support ring. The braided shielding layer of the second straight section cable is folded over at the end near the connector shell of the distribution box and then fitted onto the outer wall of the second inner liner support ring. An annular groove is provided on the outer wall of the second inner liner support ring. Corrugated pleats are pressed on the elastic claw corresponding to the rear end of the second shielding connector. The radial flange of the free end of the elastic claw is inserted into the annular groove of the second inner liner support ring and the corrugated pleat section is in a pre-compressed state. The front end of the second shielding connector is inserted into the second connector shielding shell, and the second connector shielding shell is fixedly installed on the connector shell of the distribution box.

[0021] This invention solves the technical problem of shear fatigue fracture at the root of the first terminal crimp by setting a floating ring inside the connector housing on the battery swapping interface side. The floating ring absorbs the lateral alignment deviation of the blind insertion through radial elastic deformation, so that the root of the first terminal crimp does not bear the shear force caused by the lateral deviation. Moreover, the spring terminal is arranged axially to buffer and absorb the axial insertion and extraction impact force step by step, thus achieving the technical effect of protecting the crimping part of the first terminal from the direct impact force.

[0022] Furthermore, this invention, by setting a shielding overlap structure at both ends, allows the corrugated sections in the shielding overlap structure to elastically expand and contract along the axial direction during temperature cycling. The braided shielding copper wire, the first inner lining support ring, and the first shielding connector at the shielding overlap on the battery swapping interface side compensate for the thermal expansion differences among them. Similarly, the braided shielding copper wire, the second inner lining support ring, and the second shielding connector at the shielding overlap on the battery swapping box side compensate for the thermal expansion differences among them. This ensures that the radial clamping force of the radial flange on the braided shielding layer remains stable over a wide temperature range. The spherical arc surface at the bottom of the ring groove guides the radial flange to contact in a rolling manner, eliminating fretting wear of the braided wires. This solves the technical problems of shielding contact resistance increasing with temperature cycling and local overheating under high current conditions, achieving the technical effect of maintaining stable shielding contact resistance after repeated temperature cycling. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the overall structure of the high-voltage wiring harness assembly for new energy vehicles according to the present invention;

[0024] Figure 2 This is the present invention. Figure 1 A schematic diagram of the longitudinal full-section structure;

[0025] Figure 3 This is a cross-sectional view of the connector housing, floating ring, and inner seat of the present invention.

[0026] Figure 4 This is a schematic diagram of the structure of the first shielding connector on the battery swapping interface side of the present invention;

[0027] Figure 5 This is a schematic diagram of the shielding overlap structure on the battery swapping interface side and the longitudinal cross-sectional structure of the first straight section cable of the present invention.

[0028] Figure 6 This is a longitudinal cross-sectional view of the shielding overlap structure, the first straight section cable, the connector housing, the floating ring, the inner seat, and the first terminal on the battery swapping interface side of the present invention.

[0029] In the diagram: 1. Connector housing; 2. Inner seat; 3. First terminal; 4. Floating ring; 5. Spring terminal; 6. First connector shielding shell; 7. First shielding connector; 71. Groove; 72. Elastic gripper; 8. First inner liner support ring; 9. Fold-over section; 10. Metal strip; 11. Insulating sealing sleeve; 12. First straight section cable; 13. Corrugated telescopic section; 14. Conductor bundle; 15. Insulating tube; 16. Shielding flexible tube; 17. Sheath; 18. Pressure ring; 19. Second straight section cable; 20. Distribution box connector housing; 21. Second shielding connector; 22. Second inner liner support ring; 23. Second connector shielding shell; 24. Second terminal. Detailed Implementation

[0030] The power battery pack of the battery-swapping new energy commercial vehicle is detachably connected to the vehicle body via a bottom mechanical locking mechanism. During each battery swap, the battery pack rises and falls vertically and blindly inserts into the high-voltage interface of the vehicle body. The high-voltage distribution box on the side of the vehicle body is connected to the battery swapping interface via a high-voltage wiring harness. One end of the wiring harness is fixed to the distribution box, and the other end, terminal 3, is inserted into the battery swapping interface connector. Due to the high operating temperature of the commercial vehicle's electric drive system, and the battery swapping interface being located close to the electric drive system, the wiring harness shielding overlap is subjected to temperature cycles ranging from -40 degrees Celsius to 180 degrees Celsius over a long period. At the same time, the blind insertion misalignment and insertion / removal impact force generated during each battery swap cause terminal 3 to bear a combined load.

[0031] In existing technology, the first terminal 3 of the wire harness is rigidly crimped and fixed to the connector housing, and the shield overlap adopts a common straight-cylinder elastic claw sleeve structure. During blind mating, the first terminal 3 is subjected to shear force due to lateral deviation, resulting in fatigue fracture at the crimp root. At the same time, under high-temperature cycling, the radial clamping force of the straight-cylinder claw decreases due to the difference in thermal expansion coefficients of the copper wire, inner liner ring, and connector. The braided wires experience fretting wear at the root of the claw, and the shield contact resistance increases gradually, resulting in local overheating under high current conditions.

[0032] Therefore, a high-voltage wiring harness assembly is needed that can simultaneously avoid shear fatigue fracture of the first terminal 3 and shielding failure caused by attenuation of the shielding clamping force and fretting wear of the braided wires under the combined effects of mechanical loads from blind insertion misalignment and insertion / removal impacts and thermal loads from wide temperature cycles.

[0033] This embodiment provides a high-voltage wiring harness assembly for new energy vehicles, including:

[0034] like Figure 1 As shown, the high-voltage wiring harness assembly provided in this embodiment unfolds along the wiring harness axis, with one end connected to the high-voltage distribution box on the vehicle side and the other end connected to the battery swapping interface connector. The high-voltage wiring harness assembly includes:

[0035] The first straight section cable 12 on the battery swapping interface side and the second straight section cable 19 on the distribution box side are electrically connected;

[0036] The power distribution box connector housing 20 is fixed at the power distribution box interface. (See attached document for further details.) Figure 2 The power distribution box connector housing 20 has a second terminal 24 crimped inside, and the second terminal 24 is electrically connected to the cable conductor of the second straight section cable 19.

[0037] Connector housing 1 is fixed to the power swapping interface, and a receiving cavity is provided inside connector housing 1;

[0038] Inner seat 2 is accommodated in the accommodating cavity. A first terminal 3 is fixed at the front end of the inner seat 2. A radial floating gap is reserved between the outer wall of the inner seat 2 and the inner wall of the accommodating cavity.

[0039] The floating ring 4 is fitted around the outer periphery of the inner seat 2. The floating ring 4 is inserted into the inner wall of the receiving cavity in an interference fit manner. It is used to undergo radial elastic deformation when there is a blind insertion lateral deviation, so as to allow the inner seat 2 to self-adaptively displace along a plane perpendicular to the axis within the radial floating gap.

[0040] The spring terminal 5 is connected between the rear end of the inner seat 2 and the cable conductor of the first straight section cable 12, and has elastic extension and retraction capability along the axial direction.

[0041] like Figure 2As shown, the inner layer of the second straight section cable 19 is a cross-linked polyethylene insulated copper core conductor, which is twisted in a unidirectional spiral manner. The cross-linked polyethylene insulated copper core conductor is covered with a braided shielding layer, which is then covered with a sheath. The second straight section cable 19 extends along its axial direction.

[0042] It should be noted that the inner structure of the first straight section cable 12 is the same as that of the second straight section cable 19, both using cross-linked polyethylene insulated copper core conductors, with the conductors spirally twisted in the same direction, and the outer layers successively covered with braided shielding and sheath. The first straight section cable 12 extends along the axial direction, with the end near the power exchange interface entering the connector housing 1.

[0043] Continue reading Figure 6 To maintain axial positioning and prevent axial movement of the inner seat 2 during floating, the inner wall of the connector housing 1 is machined with stepped grooves along the axial direction. Both ends of the stepped grooves have annular stepped surfaces, and the distance between the two annular stepped surfaces matches the axial width of the floating ring 4. After the floating ring 4 is installed, its two axial end faces respectively conform to the two annular stepped surfaces. The axial displacement of the inner seat 2 is limited by the friction and elastic clamping force between the floating ring 4 and the stepped surfaces.

[0044] like Figure 3 As shown, in some embodiments, the floating ring 4 is an integral annular part with a circular cross-section. It is made of fluorosilicone rubber and, after assembly, forms an elastic seal between the outer wall of the inner seat 2 and the inner wall of the receiving cavity while providing radial floating return force.

[0045] Continue reading Figure 1 A corrugated expansion section 13 is also provided between the second straight section cable 19 and the first straight section cable 12. The end of the second straight section cable 19 away from the distribution box interface is connected to the corrugated expansion section 13, and the end of the first straight section cable 12 away from the power swapping interface is connected to the corrugated expansion section 13.

[0046] Continue reading Figure 2The corrugated expansion section 13 includes a conductor bundle 14, an insulating tube 15, a shielded flexible tube 16, and a sheath 17. The innermost layer of the corrugated expansion section 13 is the conductor bundle 14, which is a spirally stranded soft copper conductor bundle. The strand pitch of the conductor bundle 14 is less than that of the conductors in the second straight section cable 19 and the first straight section cable 12, giving the conductor bundle 14 greater axial flexibility. The conductor bundle 14 is externally fitted with an insulating tube 15, and the insulating tube 15 is externally fitted with a shielded flexible tube 16. Both ends of the shielded flexible tube 16 are respectively pressed and overlapped with the braided shielding layer of the corresponding straight section cable via a pressure ring 18, achieving electrical continuity of shielding between the corrugated expansion section 13 and the two straight sections. The shielded flexible tube 16 is completely covered by the outer sheath 17 for sealing and protection. For example, the insulating tube 15 is a corrugated cross-linked polyethylene insulating tube. The crests and troughs of the insulating tube 15 maintain the same wall thickness, so that the insulating tube 15 has elastic expansion and contraction capabilities along the axial direction. In this case, the shielded flexible tube 16 is a metal spiral corrugated shielded flexible tube, and the sheath 17 is a rubber corrugated sheath.

[0047] Connector housing 1 is fixed to the vehicle body battery swapping interface with bolts, such as Figure 6 As shown, the first terminal 3 is crimped and fixed to the front end of the cylindrical inner seat 2, which is housed within the cavity of the connector housing 1. A floating ring 4 is fitted around the outer circumference of the inner seat 2. The outer diameter of the floating ring 4 is larger than the inner diameter of the cavity of the connector housing 1. During assembly, the floating ring 4 is inserted into the inner wall of the cavity with an interference fit. An annular radial floating gap is reserved between the outer wall of the inner seat 2 and the inner wall of the cavity of the connector housing 1. When a lateral misalignment occurs during blind mating, the floating ring 4 is compressed and undergoes radial elastic deformation, allowing the inner seat 2 to adaptively displace along a plane perpendicular to the axis within the radial floating gap range. After mating, the floating ring 4 elastically recovers and pushes the inner seat 2 back to the centered position. The rear end of the inner seat 2 is connected to a spring terminal 5, and the other end of the spring terminal 5 is connected to the conductor of the first straight section of cable 12. The spring terminal 5 has elastic extension and contraction capabilities along the axial direction, and is axially compressed or extended during mating to match the mating stroke.

[0048] like Figure 4 As shown, the first shielding connector 7 on the battery swapping interface side adopts a temperature-compensated corrugated elastic gripper structure. The first shielding connector 7 is sleeve-shaped, with an insertion section machined at its front end. Several axial grooves 71 are cut along the circumferential direction on the outer wall of the insertion section, dividing the insertion section into several elastic segments. Several axial grooves are evenly distributed along the circumferential direction at the rear end of the first shielding connector 7, dividing the rear end into several elastic grippers 72. Each elastic gripper 72 has a corrugated section pressed along its axial direction, forming a temperature-compensated segment; exemplarily, the corrugated section is W-shaped. The free end of each elastic gripper 72 is bent inward to form a radial flange.

[0049] Continue reading Figure 1 and Figure 2 The high-voltage wiring harness assembly also includes a shielding overlap structure disposed on the battery swapping interface side. The shielding overlap structure includes a first connector shielding shell 6, a first shielding connector 7, and an inner liner support ring 8. (Continue reading...) Figure 5 The braided shielding layer of the first straight section of cable 12 is folded at the end near the connector housing 1 in a direction away from the power exchange interface. The folded section 9 is fitted onto the outer wall of the inner liner support ring 8. The inner liner support ring 8 is an annular piece, and its outer wall is machined with annular grooves along the circumference. Figure 5 As shown, the bottom of the annular groove is spherical. The front end insertion section of the first shielding connector 7 is inserted into the inner hole of the first connector shielding shell 6. The outer wall of each elastic flap forms multi-point elastic contact with the inner wall of the first connector shielding shell 6, realizing the electrical connection between the first shielding connector 7 and the first connector shielding shell 6. During assembly, each elastic claw 72 at the rear end of the first shielding connector 7 is sleeved on the outside of the folded section 9, and each radial flange is engaged in the annular groove on the outer wall of the inner liner support ring 8. The W-shaped corrugated section is in a pre-compressed state, so that the radial flanges maintain radial clamping force on the folded section 9.

[0050] For example, the first connector shield 6 is fixed to the connector housing 1 by screws, see further. Figure 6 The first connector shield 6 is flexibly connected to the grounding terminal on the connector housing 1 via a metal strip 10. The metal strip 10 has a bending allowance. When the inner seat 2 moves radially within the radial floating gap, the metal strip 10 adapts to the displacement by bending deformation, maintaining the continuity of the shielded electrical path.

[0051] It should be noted that further reading is required. Figure 2 An insulating sealing sleeve 11 is fitted onto the outer end face of the first shielding connector 7 and the connector housing 1. The insulating sealing sleeve 11 covers the shielding overlap area of ​​the elastic clamp 72 and the folding section 9 to the end face of the connector housing 1, thereby achieving external sealing protection.

[0052] It should be further explained that you should continue to refer to [the relevant resources]. Figure 2The second terminal 24 on the distribution box side is fixed to the distribution box connector housing 20 by conventional crimping. The distribution box side is also provided with a shielding overlap structure, which includes a second connector shielding shell 23, a second shielding connector 21, and a second inner liner support ring 22. The braided shielding layer of the second straight section cable 19 is folded over at the end near the distribution box connector housing 20 and then fitted onto the outer wall of the second inner liner support ring 22. The outer wall of the second inner liner support ring 22 is also provided with an annular groove. The bottom of the annular groove is spherical. Corrugated pleats are pressed on the elastic claw 72 corresponding to the rear end of the second shielding connector 21. The radial flange at the free end of the elastic claw 72 is inserted into the annular groove of the second inner liner support ring 22 and the corrugated pleat section is in a pre-compressed state. The radial flange maintains radial clamping force on the folded braided shielding layer. The front end of the second shielding connector 21 is inserted into the second connector shielding shell 23. The second connector shielding shell 23 is fixedly installed on the distribution box connector housing 20.

[0053] Working principle

[0054] During battery swapping, the lifting device raises the battery pack vertically to the battery swapping interface at the bottom of the vehicle body, and the battery pack side plug-in terminals are blindly plugged into the first terminal 3 inside the connector housing 1 along the axial direction.

[0055] During blind mating, the battery pack side mating terminal first contacts the first terminal 3. When there is a lateral alignment deviation between the battery pack side mating terminal and the first terminal 3, the mating terminal applies a lateral force perpendicular to the axis to the first terminal 3. This lateral force is transmitted to the inner seat 2 via the first terminal 3. The inner seat 2 transmits the lateral force to the floating ring 4, which undergoes radial elastic deformation under pressure. The inner seat 2 shifts along a plane perpendicular to the axis within the radial floating gap range, allowing the first terminal 3 to adaptively adjust to the actual position of the mating terminal. The lateral displacement of the inner seat 2 is absorbed by the elastic deformation of the floating ring 4, and the crimping root of the first terminal 3 does not bear shear force.

[0056] As the terminal continues to be inserted along the axial direction, an axial insertion and extraction impact force is generated. This axial insertion and extraction impact force is transmitted to the inner seat 2 via the first terminal 3. The spring terminal 5 at the rear end of the inner seat 2 compresses along the axial direction, absorbing the axial impact stroke. At the same time, the insulating tube 15 and the shielding flexible tube 16 of the corrugated expansion section 13 elastically contract along the axial direction, and the internal conductor bundle 14 flexibly deforms accordingly, further buffering the axial impact force. The spring terminal 5 and the corrugated expansion section 13 are connected in series to absorb the axial insertion and extraction stroke, preventing the impact force from being transmitted to the crimping part of the first terminal 3.

[0057] After insertion and removal, the elastic restoring force of the floating ring 4 pushes the inner seat 2 back to the center position of the receiving cavity, the spring terminal 5 extends along the axial direction to return to the free state, and the corrugated telescopic section 13 returns synchronously.

[0058] During temperature cycling from -40°C to 180°C, the braided shielding copper wires, the inner lining support ring 8, and the first shielding connector 7 at the shield overlap on the power swapping interface side undergo differential thermal deformation due to their different coefficients of thermal expansion. The corrugated sections on the elastic claws 72 at the rear end of the first shielding connector 7 elastically expand and contract along the axial direction, absorbing the axial thermal expansion differences among the three components, ensuring that the radial flange maintains a stable radial clamping force on the folded section 9. Simultaneously, the radial flange engages in the annular groove of the inner lining support ring 8. When temperature changes cause axial thermal creep, the radial flange rolls along the spherical arc surface at the bottom of the annular groove, rather than sliding along a plane. This rolling contact prevents relative slippage between the radial flange and the braided wires, eliminating fretting wear on the braided wires. The shield overlap on the distribution box side operates in the same manner.

[0059] In some embodiments, the complete conduction process of the shielded electrical path is as follows: the current of the braided shielding layer is transmitted through the folded section 9 to the pressing contact surface of the radial flange, then through the sleeve of the first shielding connector 7 to the multi-point elastic contact surface between the front elastic flap and the inner wall of the first connector shielding shell 6, then through the first connector shielding shell 6 to the metal strip 10, and finally through the metal strip 10 to the grounding terminal of the connector housing 1, completing the shielding grounding. When the inner seat 2 moves radially within the radial floating gap, the metal strip 10 bends and deforms due to the reserved bending allowance, maintaining the electrical continuity between the first connector shielding shell 6 and the grounding terminal.

[0060] Technical effects of this embodiment

[0061] In this embodiment, the radial elastic deformation of the floating ring 4 absorbs the lateral alignment deviation of the blind insertion. The inner seat 2 adaptively moves with the mating terminals within the radial floating gap, and the crimping root of the first terminal 3 does not bear the shear force caused by the lateral deviation, thus avoiding shear fatigue fracture of the crimping root of the first terminal 3. The spring terminal 5 and the corrugated expansion section 13 are arranged in series along the axial direction, and the axial insertion and extraction impact force is gradually buffered and absorbed through elastic compression, so that the impact force does not directly act on the crimping part of the first terminal 3, further protecting the reliability of the connection of the first terminal 3.

[0062] In the temperature-compensated waveform elastic gripper structure, the corrugated section elastically expands and contracts along the axial direction during temperature cycling, compensating for the thermal expansion differences among the braided shielding copper wires, the inner lining support ring 8, and the first shielding connector 7. This ensures that the radial clamping force of the radial flange on the braided shielding layer remains stable over a wide temperature range, preventing the clamping force from attenuating with temperature cycling. The spherical arc-shaped surface at the bottom of the annular groove guides the radial flange to make rolling contact during axial thermal creep, replacing planar sliding contact. This eliminates the problem of gradual wear of the braided wires due to fretting wear, ensuring that the shielding contact resistance remains stable after repeated temperature cycling and preventing localized overheating at the shielding overlap under high current conditions.

[0063] Therefore, the structure of the floating ring 4 and the inner seat 2 works in conjunction with the waveform elastic gripper structure with temperature compensation to ensure that the end of the high-voltage harness assembly maintains the reliable electrical connection and the continuous effectiveness of the shielding path of the first terminal 3 under the combined conditions of mechanical impact load during power swapping blind insertion and thermal load during wide temperature cycles.

[0064] The embodiments of the present invention have been described above. However, the embodiments are not limited to the specific implementation methods described above. The specific implementation methods described above are merely illustrative and not restrictive. Those skilled in the art can make more equivalent embodiments under the guidance of the present embodiments, and all of them are within the protection scope of the present embodiments.

Claims

1. A high-voltage wiring harness assembly for new energy vehicles, characterized in that, include: The first straight section cable (12) on the side of the power swapping interface and the second straight section cable (19) on the side of the distribution box are electrically connected; The power distribution box connector housing (20) is fixed at the power distribution box interface. A second terminal (24) is crimped inside the power distribution box connector housing (20). The second terminal (24) is electrically connected to the cable conductor of the second straight section cable (19). The connector housing (1) is fixed at the power exchange interface, and a receiving cavity is provided inside the connector housing (1); The inner seat (2) is housed in the receiving cavity. The front end of the inner seat (2) is fixed with a first terminal (3). A radial floating gap is reserved between the outer wall of the inner seat (2) and the inner wall of the receiving cavity. A floating ring (4) is fitted around the outer periphery of the inner seat (2). The floating ring (4) is inserted into the inner wall of the receiving cavity in an interference fit manner. It is used to undergo radial elastic deformation when there is a blind insertion lateral deviation, so as to allow the inner seat (2) to self-adaptively displace along a plane perpendicular to the axis within the radial floating gap. The spring terminal (5) is connected between the rear end of the inner seat (2) and the cable conductor of the first straight section cable (12), and has elastic extension and retraction capability along the axial direction.

2. The high-voltage wiring harness assembly for new energy vehicles according to claim 1, characterized in that, The inner wall of the receiving cavity of the connector housing (1) is provided with a stepped groove along the axial direction. The two ends of the stepped groove in the axial direction have annular stepped surfaces. When the floating ring (4) is installed in the stepped groove, the two axial end faces of the floating ring (4) respectively fit with the two annular stepped surfaces.

3. The high-voltage wiring harness assembly for new energy vehicles according to claim 1, characterized in that, It also includes a corrugated expansion section (13), which is located between the second straight section cable (19) and the first straight section cable (12) on the side of the distribution box. The corrugated expansion section (13) includes a conductor bundle (14), an insulating tube (15), a shielding hose (16) and a sheath (17). The conductor bundle (14) is fitted with an insulating tube (15), the insulating tube (15) is fitted with a shielding hose (16), and the shielding hose (16) is covered with a sheath (17). The two ends of the conductor bundle (14) are electrically connected to the cable conductors of the second straight section cable (19) and the cable conductors of the first straight section cable (12), respectively.

4. The high-voltage wiring harness assembly for new energy vehicles according to claim 3, characterized in that, The strand pitch of the conductor bundle (14) is less than the strand pitch of the cable conductor in the second straight section cable (19) and the strand pitch of the cable conductor in the first straight section cable (12). The insulating tube (15) is a corrugated insulating tube with the same wall thickness at the crest and trough. The two ends of the shielding hose (16) are respectively pressed and overlapped with the braided shielding layer of the corresponding straight section cable through the pressure ring (18).

5. The high-voltage wiring harness assembly for new energy vehicles according to claim 1, characterized in that, It also includes a shielding overlap structure set on the battery swapping interface side. The shielding overlap structure includes a first connector shielding shell (6), a first shielding connector (7) and a first inner liner support ring (8). The braided shielding layer of the first straight section cable (12) is folded at the end near the connector shell (1) to form a folded section (9). The folded section (9) is fitted onto the outer wall of the first inner liner support ring (8). The rear end of the first shielding connector (7) is fitted onto the outer wall of the folded section (9). The front end of the first shielding connector (7) is inserted into the first connector shielding shell (6). The first connector shielding shell (6) is fixedly installed on the connector shell (1).

6. The high-voltage wiring harness assembly for new energy vehicles according to claim 5, characterized in that, The outer wall of the first inner liner support ring (8) is provided with an annular groove along the circumference. The first shielding connector (7) is sleeve-shaped. The front end of the first shielding connector (7) is provided with an insertion section. The outer wall of the insertion section is provided with several axial grooves (71) along the circumference to divide the insertion section into several elastic petals. The outer wall of each elastic petal is in elastic contact with the inner wall of the first connector shielding shell (6). The rear end of the first shielding connector (7) is provided with several axial grooves along the circumference to divide the rear end into several elastic claws (72). Each elastic claw (72) is pressed with corrugated folds along the axial direction. The corrugated folds of each elastic claw (72) are bent inward to form a radial flange.

7. The high-voltage wiring harness assembly for new energy vehicles according to claim 6, characterized in that, Each elastic claw (72) at the rear end of the first shielding connector (7) is fitted onto the outside of the folded section (9), and each radial flange is inserted into the annular groove on the outer wall of the first inner lining support ring (8).

8. The high-voltage wiring harness assembly for new energy vehicles according to claim 5, characterized in that, The first connector shield (6) is flexibly connected to the grounding terminal on the connector housing (1) by a metal strip (10). The metal strip (10) has a bending allowance to maintain the continuity of the shielded electrical path by bending deformation when the inner seat (2) is radially displaced.

9. The high-voltage wiring harness assembly for new energy vehicles according to claim 5, characterized in that, An insulating sealing sleeve (11) is fitted on the outer end face of the first shielding connector (7) and the connector housing (1), and the insulating sealing sleeve (11) covers the shielding overlap area of ​​the elastic claw (72) and the folded section (9) to the surface of the braided shielding layer of the first straight section cable (12).

10. The high-voltage wiring harness assembly for new energy vehicles according to claim 6, characterized in that, It also includes a shielding overlap structure set on the side of the distribution box. The shielding overlap structure on the side of the distribution box includes a second connector shielding shell (23), a second shielding connector (21), and a second inner liner support ring (22). The braided shielding layer of the second straight section cable (19) is folded over at the end near the distribution box connector shell (20) and then fitted onto the outer wall of the second inner liner support ring (22). The outer wall of the second inner liner support ring (22) has an annular groove. Corrugated pleats are pressed on the elastic claw (72) corresponding to the rear end of the second shielding connector (21). The radial flange of the free end of the elastic claw (72) is inserted into the annular groove of the second inner liner support ring (22) and the corrugated pleat section is in a pre-compressed state. The front end of the second shielding connector (21) is inserted into the second connector shielding shell (23). The second connector shielding shell (23) is fixedly installed on the distribution box connector shell (20).

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