High-voltage wiring harness

Abstract

The utility model provides a high-voltage wire harness, which comprises a wire harness body and an adapter, the wire harness body comprises a first wire harness and a second wire harness, the first wire harness is an aluminum wire, the second wire harness is a copper wire, the first wire harness and the second wire harness are mutually connected through the adapter, and one end of the second wire harness deviating from the first wire harness is used for being electrically connected with a high-voltage vibration piece. According to the high-voltage wire harness, the first wire harness with the conductor material being aluminum and the second wire harness with the conductor material being copper are combined into the wire harness body, so that the problem that the high-voltage wire harness singly using an aluminum wire cannot be applied to a vibrating piece is solved, the high strength of the original copper wire is reserved, and the purpose that aluminum is replaced by copper is achieved; the overall weight is reduced, and meanwhile the production cost is reduced.

Description

Technical Field

[0001] The utility model relates to the technical field of vehicle wiring harnesses, in particular to a high-voltage wiring harness. Background Art

[0002] At present, new energy vehicles are developing rapidly, and the demand for lightweight design of automobiles is further increased. Compared with traditional oil vehicles, pure electric vehicles have added a large number of high-voltage wiring harnesses, such as DC fast charging wiring harnesses, DC busbars, MCU wiring harnesses, etc. These wiring harnesses are the main components of automotive power transmission. The traditional design uses copper alloy as the conductor material, but copper alloy is not only dense but also expensive. The prior art uses wiring harnesses with aluminum alloy as the conductor material. Aluminum wires have low cost and low density, and are currently the preferred measure for reducing the weight and cost of automotive wiring harnesses. However, the strength of aluminum wires themselves is relatively low. At present, the application of aluminum wires in the market is still limited to static high-voltage wiring harnesses, and has not yet been applied to dynamic vibrating parts connected to motors. Utility Model Content

[0003] In order to overcome the defects in the above-mentioned background technology, the utility model aims to provide a high-voltage wire harness with low density, low cost and suitable for connecting dynamic vibrating parts.

[0004] The technical solution for achieving the purpose of the present invention is as follows: the present invention provides a wiring harness body and an adapter, the wiring harness body includes a first wiring harness and a second wiring harness, the first wiring harness is an aluminum wire, the second wiring harness is a copper wire, the first wiring harness and the second wiring harness are connected to each other through the adapter, and the end of the second wiring harness facing away from the first wiring harness is used to electrically connect to a high-voltage vibrator.

[0005] In one embodiment of the utility model, the high-voltage wiring harness also includes a first connecting member and a second connecting member, the first connecting member and the second connecting member are fixedly connected to the two ends of the wiring harness body, and the wiring harness body is electrically connected to the high-voltage vibration member through the first connecting member and / or the second connecting member.

[0006] In an embodiment of the present invention, the first connecting member is an IPT connector, and the second connecting member is a sheet-type connector.

[0007] In an embodiment of the present invention, the distance between the adapter and the second connecting member is 0.20m to 0.30m.

[0008] In one embodiment of the present invention, the radial cross-sectional area of ​​the aluminum conductor is 65 mm 2 ~75mm 2 , the radial cross-sectional area of ​​the copper wire is 45mm 2 ~55mm 2 .

[0009] In an embodiment of the present invention, the high-voltage wire harness further includes a protective cover, which is disposed on the first wire harness and the second wire harness, and is used to protect the first wire harness and the second wire harness from mechanical impact and wear.

[0010] In an embodiment of the present invention, the protective cover is a braided mesh tube.

[0011] In an embodiment of the present invention, the high-voltage wire harness further includes a clamping piece, the first wire harness has two, the second wire harness has two, and the clamping piece is used to fix two of the first wire harnesses or the second wire harnesses.

[0012] In an embodiment of the present utility model, the high-voltage wire harness further includes a bracket, the bracket is fixedly connected to the vehicle body floor, and the adapter is fixedly connected to the bracket.

[0013] In one embodiment of the utility model, the bracket includes a first section, a second section and a third section connected in sequence, the first section and the third section are parallel to each other, the first section is fixedly connected to the adapter, and the third section is fixedly connected to the vehicle body floor.

[0014] The beneficial effects produced by the utility model and the prior art are as follows: in the high-voltage wire harness of the utility model, by combining the first wire harness whose conductor material is aluminum and the second wire harness whose conductor material is copper into a composite wire harness body, the problem that the high-voltage wire harness using only aluminum wire cannot be applied to the vibration part is solved, which not only retains the high strength of the original copper wire, but also replaces aluminum with copper, reduces the overall weight, and reduces the production cost at the same time. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 The figure is a schematic structural diagram of a high voltage wire harness according to an embodiment of the utility model.

[0016] Figure 2 for Figure 1 A partial enlarged view of middle A.

[0017] Figure 3 for Figure 1 A partial enlarged view of B.

[0018] Figure 4 for Figure 1 A partial enlarged view of C in the middle.

[0019] Figure 5 for Figure 1 A schematic structural diagram of the bracket of the high-voltage wiring harness is shown. DETAILED DESCRIPTION

[0020] The following is a further detailed description of the specific implementation of the present invention in conjunction with the accompanying drawings and examples. The following examples are used to illustrate the present invention, but are not intended to limit the scope of the present invention.

[0021] The utility model provides a wiring harness, such as Figure 1-2 As shown, a high-voltage wire harness in an embodiment includes a wire harness body 11 and an adapter 12. The wire harness body 11 includes a first wire harness 111 and a second wire harness 112. The first wire harness 111 is an aluminum wire, and the second wire harness 112 is a copper wire. At least one of the two ends of the first wire harness 111 is connected to the second wire harness 112. The adapter 12 is used to make the line unobstructed and ensure the safe operation of the circuit. The first wire harness 111 and the second wire harness 112 are interconnected through the adapter 12. Both the first wire harness 111 and the second wire harness 112 can be electrically connected to electronic equipment to realize the transmission of power, signals and data, wherein the end of the second wire harness 112 facing away from the first wire harness 111 is electrically connected to the high-voltage vibrator.

[0022] It should be noted that the first wire harness 111 is formed by bundling a plurality of aluminum wires, and the second wire harness 112 is formed by bundling a plurality of copper wires. The high-voltage wire harness in this embodiment is an MCU (Microcontroller Unit) wire harness.

[0023] The high-voltage vibration component in this embodiment specifically refers to electronic equipment such as motors, electronic controls and reducers.

[0024] In this embodiment, the harness body 11 of the high-voltage harness is composed of two sections, a first harness 111 and a second harness 112, which are connected to each other through an adapter 12. One end of the first harness 111 away from the adapter 12 and one end of the second harness 112 away from the adapter 12 are electrically connected to the electronic device respectively. Among them, one end of the second harness 112 away from the adapter 12 is electrically connected to a high-voltage vibrator (such as a motor), which can resist the vibration generated by the high-voltage vibrator to a large extent.

[0025] It can be understood that the wiring harness body 11 can also be composed of three sections, namely, the second wiring harness 112, the first wiring harness 111 and the second wiring harness 112. The first wiring harness 111 and the second wiring harness 112 are connected to each other through the adapter 12. The two second wiring harnesses 112 located at both ends of the first wiring harness 111 can be electrically connected to the high-voltage vibrating component to resist the vibration generated by the high-voltage vibrating component. The material of the middle part of the wiring harness that does not need to be electrically connected to the high-voltage vibrating component is replaced from copper wire to aluminum wire, which reduces the overall weight of the wiring harness body 11 and also reduces the cost.

[0026] In this embodiment, the length of a single copper wire is 0.25 m, and the length of a single aluminum wire is 2.75 m.

[0027] In the high-voltage wire harness of the utility model, by combining the first wire harness 111 whose conductor material is aluminum and the second wire harness 112 whose conductor material is copper into a wire harness body 11, the problem that the high-voltage wire harness using only aluminum wire cannot be applied to the vibration part is solved, which not only retains the high strength of the original copper wire, but also realizes the use of copper instead of aluminum, reduces the overall weight, and reduces the production cost at the same time.

[0028] In this embodiment, the adapter 12 may be an adapter box. The adapter 12 is a key connector, which is designed according to the connected first wire harness 111 and second wire harness 112, and is designed to meet performance technical requirements, including vibration, EMC (electromagnetic shielding) and waterproof requirements.

[0029] When the first wiring harness 111 and the second wiring harness 112 are connected via an adapter box, the main function of the adapter box is to make the line unobstructed and ensure the safe operation of the circuit. Especially when the line is relatively long or the wire tube needs to turn a corner, the adapter box is very practical as a transition tool. For example, in home decoration, the wires will pass through the wire tube, and at this time, a junction box is required between the wire tube and the joint. After the wire tube is connected to the junction box, the wires in the wire tube are connected in the junction box, which not only protects the wires but also realizes the connection of the wires.

[0030] In this embodiment, Figure 3-4 As shown, the high-voltage wiring harness also includes a first connector 13 and a second connector 14, which are fixedly connected to both ends of the wiring harness body 11. The wiring harness body 11 is electrically connected to the electronic device through the first connector 13 and the second connector 14 to achieve transmission of power, signals and data.

[0031] Specifically, the first connector 13 is an IPT (Inductive Power Transfer) connector. The IPT connector can enhance the EMC (Electromagnetic Compatibility) performance and provide a low contact resistance shielding layer. This is very important for high-voltage applications running in electric vehicles, because it can effectively prevent electromagnetic interference and ensure the normal operation of the equipment. Secondly, the IPT connector has a sealing level of IP67, IP68 and IP6K9K. This means that they can prevent dust, moisture and other harmful substances from entering the connector, thereby ensuring the stable operation of the connector and the electrical system. Especially in hybrid vehicles or electric vehicles, such a level of protection is particularly important. In addition, IPT connectors can also improve assembly efficiency. Because they adopt a single harness design and have a convenient mounting hole processing process, they can significantly simplify the assembly process and save production time. At the same time, the IPT connector provides flexible wire selection, and 50mm can be selected according to specific application requirements. 2、70mm 2 and 95mm 2 In general, the use of IPT connectors at the ends of high-voltage wire harnesses can improve the performance and reliability of the electrical system, while also improving production efficiency.

[0032] Specifically, the second connector 14 is a sheet connector. Due to the compact design of sheet connectors, they can save space, which is very important for equipment that needs to be installed in a small or narrow space. Secondly, this type of connector provides good electrical performance, which can effectively prevent electromagnetic interference and ensure the normal operation of the equipment. In addition, the sheet connector also has excellent protection performance, which can prevent dust, moisture and other harmful substances from entering the connector, thereby ensuring the stable operation of the connector and the electrical system. At the same time, the use of sheet connectors can also improve assembly efficiency. Because they adopt a modular design and have a convenient installation method, the assembly process can be significantly simplified and production time can be saved. In addition, sheet connectors also have good heat resistance and vibration resistance, which enables them to work stably in various harsh environments. In general, the use of sheet connectors at the end of the high-voltage wiring harness can improve the performance and reliability of the electrical system, while also improving production efficiency.

[0033] In this embodiment, the first connecting member 13 is fixedly connected to the first wire harness 111 by ultrasonic welding, and the second connecting member 14 is fixedly connected to the second wire harness 112 by ultrasonic welding.

[0034] In this embodiment, the leftmost end of the harness body 11 (at the first connector 13) is a two-in-one end, namely, PDU (Power Distribution Unit, in this embodiment, a high-voltage distribution box) and DCDC (DC-to-DC converter, in this embodiment, a DC-DC converter); the rightmost end of the harness body 11 (at the second connector 14) is a three-in-one end, namely, a motor, an electronic control, and a reducer. It should be noted that the MCU in this embodiment is an electronic control.

[0035] In this embodiment, the distance between the adapter 12 and the second connector 14 is 0.20m to 0.30m. Those skilled in the art can set the distance to 0.20m, 0.21m, 0.23m, 0.24m, 0.25m, 0.27m, 0.29m, 0.30m, etc. according to actual conditions, and this is not a sole limitation.

[0036] Specifically, the distance between the adapter 12 and the second connecting member 14 in this embodiment is 0.25 m. Placing the adapter 12 at this position can better absorb the vibration energy of the high-voltage vibrating member during the vibration process.

[0037] When the high-voltage wire harness is working, the first wire harness 111 is in a static process, and the second wire harness 112 is in a dynamic process. The second wire harness 112 can be connected to vibration parts such as motors to effectively absorb vibration energy, realizing the application of aluminum wires on high-voltage vibration parts. At the same time, the high-voltage wire harness as a whole can achieve weight reduction and cost reduction.

[0038] In this embodiment, the radial cross-sectional area of ​​the aluminum conductor is 65 mm 2 ~75mm 2 , the radial cross-sectional area of ​​the copper conductor is 45mm 2 ~55mm 2 The technicians in this field can set the radial cross-sectional area of ​​the aluminum wire to 65mm according to the actual situation. 2 、66mm 2 、68mm 2 、69mm 2 , 70mm 2 、71mm 2 、73mm 2 、74mm 2 , 75mm 2 The technicians in this field can set the radial cross-sectional area of ​​the copper wire to 45mm according to the actual situation. 2 、46mm 2 、47mm 2 、49mm 2 , 50mm 2 、52mm 2 、53mm 2 、55mm 2 Etc.; this is not the only limitation.

[0039] It should be noted that the radial cross-sectional area of ​​the aluminum wire mentioned above refers to the radial cross-sectional area of ​​a single aluminum wire, and the radial cross-sectional area of ​​the copper wire refers to the radial cross-sectional area of ​​a single copper wire.

[0040] In this embodiment, the high-voltage wire harness further includes a protective cover, which is disposed on the first wire harness 111 and the second wire harness 112 , and is used to prevent the first wire harness 111 and the second wire harness 112 from mechanical impact and wear.

[0041] In another preferred embodiment, the protective cover can be a braided mesh tube. Most existing protective covers are corrugated tubes. Replacing the corrugated tube with a braided mesh tube can better save layout space.

[0042] In this embodiment, there are two first wire harnesses 111 and two second wire harnesses 112 .

[0043] In this embodiment, the high-voltage wire harness further includes a clamping member 16, which is used to fix the two first wire harnesses 111 or the second wire harnesses 112. The two first wire harnesses 111 are fixed side by side by the clamping member 16, and the two second wire harnesses 112 are fixed side by side by the clamping member 16. The clamping members 16 of different specifications and sizes can be set according to different wire diameters.

[0044] In another preferred embodiment, Figure 5 As shown, the high-voltage wiring harness also includes a bracket 17, the bracket 17 is fixedly connected to the vehicle's body floor, and the adapter 12 is fixedly connected to the bracket 17. When the wiring harness body 11 is electrically connected to an electronic component (such as a motor), the motor will generate vibrations during operation, thereby driving the adapter 12 to float up and down, which may cause the adapter 12 to crack and burn. Therefore, by providing a bracket 17 to support the adapter 12, that is, the adapter 12 is fixedly connected to the bracket 17, and at the same time, the bracket 17 is fixedly connected to the vehicle's body floor, it is possible to prevent the electronic components such as motors that have large vibrations during operation from driving the adapter 12 to float up and down, thereby avoiding the risk of cracking and burning.

[0045] Specifically, the bracket 17 includes a first section 171, a second section 172 and a third section 173 connected in sequence. The first section 171 and the third section 173 are parallel to each other. The first section 171 is fixedly connected to the adapter 12, and the third section 173 is fixedly connected to the vehicle body bottom plate. The second section 172 can effectively resist the vibration generated by the high-pressure vibrating part during operation, and plays a role in vibration reduction.

[0046] According to the current-carrying curve, because the conductivity of aluminum alloy is 60% of that of copper alloy, under the condition of meeting the same current-carrying capacity, the high-voltage wire harness is changed from the original 50mm2 copper wire to 70mm2 aluminum wire; the left side is the two-in-one end (PDU and DCDC end), the right side is the three-in-one end (motor, electronic control and reducer end), and a new adapter box is added in the middle. The adapter box is located 0.25m away from the MCU end. The left side of the adapter box is 70mm2 aluminum wire (5.5m long) and the right side is the original 50mm2 copper wire (0.5m long). The adapter box is connected to the copper-aluminum wires at both ends by ultrasonic welding. The PDU-end socket model and the MCU-end socket and plug do not need to be changed, only some clips need to be changed to adapt to the change in wire diameter. At the same time, in order to better save layout space, the corrugated tube is changed to a braided mesh tube, so as to meet the space requirements in terms of layout direction and not interfere with surrounding parts. In addition, in order to prevent the motor vibration from causing the adapter box to float up and down, thereby starting the risk of cracking and heat accumulation, a new bracket is added to support the adapter box and fix it to the bottom plate of the vehicle body.

[0047] In this document, unless otherwise specified or limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms can be understood according to specific circumstances.

[0048] In this document, the directions or positional relationships indicated by terms such as "up", "down", "front", "back", "left", "right", "top", "bottom", "inside", "outside", "vertical", and "horizontal" are based on the directions or positional relationships shown in the accompanying drawings and are only for the clarity of the technical solution and the convenience of description. Therefore, they should not be understood as limitations on the present invention.

[0049] In this document, the terms "comprises," "comprising," or any other variations thereof, are intended to cover a non-exclusive inclusion of elements other than those listed and may also include additional elements not expressly listed.

[0050] The above is only a specific implementation of the utility model, but the protection scope of the utility model is not limited thereto. Any technician familiar with the technical field can easily think of changes or substitutions within the technical scope disclosed by the utility model, which should be included in the protection scope of the utility model. Therefore, the protection scope of the utility model should be based on the protection scope of the claims.

Claims

1. A high voltage wire harness, characterized in that: The invention comprises a wiring harness body (11) and an adapter (12), wherein the wiring harness body (11) comprises a first wiring harness (111) and a second wiring harness (112), wherein the first wiring harness (111) is an aluminum wire, and the second wiring harness (112) is a copper wire, wherein the first wiring harness (111) and the second wiring harness (112) are connected to each other via the adapter (12), and an end of the second wiring harness (112) facing away from the first wiring harness (111) is used for electrically connecting to a high-voltage vibration component.

2. The high voltage wire harness according to claim 1, characterized in that: The high-voltage wire harness further comprises a first connecting member (13) and a second connecting member (14), wherein the first connecting member (13) and the second connecting member (14) are fixedly connected to two ends of the wire harness body (11), and the wire harness body (11) is electrically connected to the high-voltage vibrating member via the first connecting member (13) and / or the second connecting member (14).

3. The high voltage wire harness according to claim 2, characterized in that: The first connecting member (13) is an IPT connector, and the second connecting member (14) is a sheet-type connector.

4. The high voltage wire harness according to claim 2, characterized in that: The distance between the adapter (12) and the second connecting member (14) is 0.20 m to 0.30 m.

5. The high voltage wire harness according to claim 1, characterized in that: The radial cross-sectional area of ​​the aluminum conductor is 65 mm 2 ~75mm 2 , the radial cross-sectional area of ​​the copper wire is 45mm 2 ~55mm 2 .

6. The high voltage wire harness according to claim 1, characterized in that: The high-voltage wire harness further comprises a protective cover, which is provided on the first wire harness (111) and the second wire harness (112), and is used to prevent the first wire harness (111) and the second wire harness (112) from mechanical impact and wear.

7. The high voltage wire harness according to claim 6, characterized in that: The protective cover is a braided mesh tube.

8. The high voltage wire harness according to claim 1, characterized in that: The high-voltage wire harness further comprises a clamping member (16), there are two first wire harnesses (111), and there are two second wire harnesses (112), and the clamping member (16) is used to fix two first wire harnesses (111) or two second wire harnesses (112).

9. The high voltage wire harness according to claim 1, characterized in that: The high-voltage wire harness also includes a bracket (17), the bracket (17) is fixedly connected to the vehicle body floor, and the adapter (12) is fixedly connected to the bracket (17).

10. The high voltage wire harness according to claim 9, characterized in that: The bracket (17) comprises a first section (171), a second section (172) and a third section (173) connected in sequence, the first section (171) and the third section (173) are parallel to each other, the first section (171) is fixedly connected to the adapter (12), and the third section (173) is fixedly connected to the vehicle body bottom plate.

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