Modularized new-structure power supply high-power wire harness

Abstract

The utility model discloses a modularized power supply high-power wire harness with a novel structure, which is characterized in that a BVR wire with a sectional area of 2.5 mm < 2 > is selected, the wire is cut according to a wiring path, the total length of the cut wire is redundant, and the head stripping length of the wire is 6mm, so that the modularized wire harness is formed; one end of the wire harness is provided with seven FDFN2-250 terminals; six C45-6 terminals and an OT2.5-4 cold-pressed terminal are arranged at the other end of the connector; and the cold-pressed terminal adopts a heat-shrinkable tube sheath. The wire harness is sleeved with a tinned and tinned woven shielding copper net sleeve with a copper wire of 0.15 mm and a width of 18 mm, two ends of the shielding copper net sleeve are grounded, a tap at one end is 30 mm, a tap at the other end is 40 mm, the shielding copper net sleeve is respectively connected with an OT5-4 cold-pressed terminal in a pressing mode, and a heat shrink tube is used for protecting the shielding copper net sleeve. Input and output interface wiring connection of the space is reasonably limited, and power supply capacity and performance safety are guaranteed; the signal anti-interference performance is achieved, processing is easy to achieve, the good processing technology method is achieved, the wire harness size is reasonable, overall wiring is met, and the production labor cost and the material cost are greatly reduced.

Description

Technical Field

[0001] The utility model relates to a power supply device, in particular to a high-power wiring harness of a power supply with a new modular structure. Background Art

[0002] With the development of electronic science and technology, more integrated, larger current, smaller and thinner power supply technology is presented, and power supply equipment is diversified and high-density, which puts forward higher requirements on the internal layout, external dimensions and installation methods of the power supply. The 4U30kW high-power bipolar power supply is mainly composed of 3 high-power high-precision module units on the bottom plate, the human-machine interaction unit on the front panel, the external interface unit on the rear panel, and the embedded control unit on the top layer. The power supply line of the power supply system is from the "RP-AC-Iput" three-phase input terminal board assembly on the rear panel to the "63A / VCF3C" AC power isolation switch on the front panel. The power supply is 2 groups of 7-wire 380V AC lines. Only a narrow channel with a width of 7.5mm and a length of 680mm is left in the casing. It is necessary to meet the performance of efficient transmission lines, take into account the structural layout and optimize the assembly process, ensure the high-quality power supply and reliability of the product, and comprehensively analyze various control factors based on risk thinking.

[0003] Aiming at connecting 2 groups of 380V power lines in a narrow and limited space of 4U30kW high-power bipolar power supply with a width of 7.5mm*length of 680mm, the wiring process solution requirements are proposed: reasonable process layout design to ensure high-quality current and voltage stable output, considering interference and coupling between systems, the material, cross-sectional area and size design of the wires, with efficient and fast operation, the 7 wires cannot be gathered into a conventional cable type, but are changed to a single-line flat sheet type, with reliable protection against safe overvoltage, overcurrent and overheating; meet product reliability, improve product performance parameters, and have an overall beautiful appearance, suitable for mass production, low-cost control and convenient after-sales disassembly and maintenance.

[0004] It is difficult for products in the prior art to meet the above requirements.

[0005] In view of this, the present utility model is proposed. Utility Model Content

[0006] The utility model aims to provide a high-power wiring harness with a modular new structure to solve the above-mentioned technical problems existing in the prior art.

[0007] The purpose of this utility model is achieved through the following technical solutions:

[0008] The modular new structure power supply high power harness of this utility model uses BVR wire with a cross-sectional area of ​​2.5mm 2 , cutting wires according to the wiring path, leaving redundancy in the total length of wire cutting, and the wire stripping length is 6mm, forming a modular wiring harness;

[0009] One end of the wiring harness has seven FDFN2-250 terminals; the other end has six C45-6 terminals and an OT2.5-4 cold-pressed terminal, which is covered with a heat shrink tube.

[0010] Compared with the prior art, the modular new structure power supply high-power wiring harness provided by the utility model is used in the high-power bipolar power supply interface. The modular new structure power supply high-power wiring harness in the narrow physical structure space reasonably limits the space of the input and output interface wiring connection to ensure the power supply capacity and performance safety; the signal anti-interference is achieved, and the processing is easy to realize. The wiring harness reduces the number of inventory parts codes, effectively improves the turnover rate of materials, simplifies the production and assembly processes, and also improves the overall quality of the product warehousing qualification rate. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1 A schematic diagram of high-power wiring harness wiring for a modular new structure power supply provided by an embodiment of the utility model;

[0012] Figure 2 This is a schematic diagram of the processing dimensions of an embodiment of the utility model.

[0013] In the figure:

[0014] 1. FDFN2-250 terminal, 2. Amorphous magnetic ring, 3. External flat heat shrink plastic seal length 70 to 80 mm, 4. Insulation tape wrapping length about 0 to 50 mm, inner insulation tape wrapping shielding layer and tap two circles, 5. Shielded copper mesh sleeve, 6. C45-6 terminal, 7. OT2.5-4 cold-pressed terminal, 8. OT5-4 cold-pressed terminal. DETAILED DESCRIPTION

[0015] The following is a clear and complete description of the technical solutions in the embodiments of the utility model in conjunction with the drawings in the embodiments of the utility model; it is obvious that the described embodiments are only part of the embodiments of the utility model, not all of the embodiments, which does not constitute a limitation of the utility model. Based on the embodiments of the utility model, all other embodiments obtained by ordinary technicians in this field without creative work are within the protection scope of the utility model.

[0016] First, the terms that may be used in this article are explained as follows:

[0017] The term “and / or” means that either or both of them can be realized at the same time. For example, X and / or Y means both “X” or “Y” and “X and Y”.

[0018] The terms "include", "comprises", "contains", "has" or other descriptions with similar semantics should be interpreted as non-exclusive inclusion. For example, including certain technical feature elements (such as raw materials, components, ingredients, carriers, dosage forms, materials, dimensions, parts, components, mechanisms, devices, steps, procedures, methods, reaction conditions, processing conditions, parameters, algorithms, signals, data, products or products, etc.) should be interpreted as including not only certain technical feature elements explicitly listed, but also other technical feature elements known in the art that are not explicitly listed.

[0019] The term "consisting of..." means excluding any technical feature elements not explicitly listed. If this term is used in a claim, it will make the claim closed, so that it does not contain technical feature elements other than the technical feature elements explicitly listed, except for the conventional impurities related to them. If this term only appears in a clause of a claim, it only limits the elements explicitly listed in the clause, and the elements recorded in other clauses are not excluded from the overall claim.

[0020] Unless otherwise specified or limited, the terms "installed", "connected", "connected", "fixed" and the like 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 it can be 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 in this article can be understood according to specific circumstances.

[0021] The orientation or position relationship indicated by terms such as "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise", etc. are based on the orientation or position relationship shown in the drawings and are only for the convenience and simplification of description, and do not explicitly or implicitly indicate that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation of this document.

[0022] The contents not described in detail in the examples of the present utility model belong to the prior art known to professionals in the field. If no specific conditions are specified in the examples of the present utility model, the conditions are carried out according to the conventional conditions in the field or the conditions recommended by the manufacturer. If the manufacturers of the reagents or instruments used in the examples of the present utility model are not specified, they are all conventional products that can be purchased commercially.

[0023] The modular new structure power supply high power harness of this utility model uses BVR wire with a cross-sectional area of ​​2.5mm 2, cutting wires according to the wiring path, leaving redundancy in the total length of wire cutting, and the wire stripping length is 6mm, forming a modular wiring harness;

[0024] One end of the wiring harness has seven FDFN2-250 terminals; the other end has six C45-6 terminals and an OT2.5-4 cold-pressed terminal, which is covered with a heat shrink tube.

[0025] The harness jacket has a tinned braided shielded copper mesh with a copper wire of 0.15mm and a width of 18mm. Both ends of the shielded copper mesh are grounded, one end has a tap of 30mm, and the other end has a tap of 40mm. They are crimped with OT5-4 cold-pressed terminals and covered with heat shrink tubing.

[0026] The 7 wire harnesses in the shielded copper mesh cannot cross or overlap. The main body of the wire harness is arranged in a single row of flat sheets, and the thickness of the shielding sheath is 6.8mm.

[0027] The shielded copper mesh is reinforced by glue spotting at the separation section, using ZR706 dealcoholized bonding silicone, and high-temperature tape and insulating tape to assist in reinforcing the protective wiring harness and hot-dip tin shrink tube to form a solidified flat shape structure.

[0028] The seven FDFN2-250 terminal ends pass through three RH14*15*9 amorphous magnetic rings, and the magnetic rings are located close to the input interface of the three-phase filter board.

[0029] The wiring harness provides two sets of 380V AC power, the power is 30KW, and the rated voltage is 450V / 750V;

[0030] The color of the protective ground wire insulation layer PE is green and yellow, the color of the neutral wire insulation layer N is light blue, the color of the phase wire insulation layer L1 is yellow, L2 is green, and L3 is red.

[0031] In summary, it can be seen that the modular new structure power supply high-power wiring harness of the embodiment of the utility model is suitable for the modular new structure power supply high-power wiring harness in harsh and narrow spaces in the 4U30kW high-power bipolar power supply system.

[0032] Make full use of space, reduce redundant wiring, implement modular high-power wiring harnesses, follow the three design principles of "universalization, serialization, and interchangeability", meet the "interface and interchangeability requirements", use the least time, the most economical investment, and the most mature technology to implement product interface standards and implementation requirements, and develop new process methods with good applicability. The wiring harness has three efficient ways to shield electromagnetic interference: one is to ground the wire harness system well; the second is to add a shielding sleeve to the outside of the wire; the third is to add an electromagnetic interference filter from the source interface. The modular new structure wiring harness is quantitatively tailored from the wire cross-sectional area, temperature requirements, flexibility, and optimized anti-interference shielding effect to avoid excessive size and excessive components. The overall size of the wiring harness fully matches the narrow use environment space.

[0033] It can be seen from the technical process scheme provided by the utility model that the wiring harness structure layout meets the wiring space requirements, the materials must be reasonably and perfectly matched and combined to ensure the normal input of the high-efficiency voltage and current of the 4U30kW high-power bipolar power supply, while taking into account assembly wiring, stable performance, low investment, reasonable labor cost, and easy processing.

[0034] The modular structure wiring harness meets the requirements of the working environment conditions, ensuring that the electrical performance parameters of the product will not be reduced, while meeting safety and environmental protection requirements.

[0035] Both ends of the wiring harness are reliable and stable, with certain mechanical strength, considering the actual wiring distance, leaving reasonable redundancy, the line length is appropriate, the direction is correct, with error-proof process design, neat and reasonable, saving assembly and wiring time.

[0036] The wire harness can be enhanced with a shielded magnetic ring at the power input interface and a braided hard shielding sleeve can be added to the wire harness. The taps on both sides of the shielding net are grounded to ensure the correct equipotential connection, isolate the electromagnetic field noise source from the sensitive equipment, and cut off the propagation path of the noise source. A lower critical resistance is obtained to reduce unnecessary mutual interference between the various subsystems.

[0037] Shielded wire harnesses are mainly composed of compliant connectors, compliant cables, coverings, and magnetic rings. Wire harness wiring, safety, shielding, weight, and cost must be comprehensively considered to become a cost-effective component, contributing to product cost reduction and efficiency improvement.

[0038] The module wiring harness has a good appearance, without burrs, breakages or mechanical damage, and is beautiful overall with clear markings.

[0039] The wiring harness conductivity rate is 100%, with no short circuit or wrong circuit phenomenon; the terminals are crimped firmly and the pulling force should meet the technical safety requirements.

[0040] The utility model discloses a modular structured high-voltage wiring harness and an innovative process method for a modular new structure power supply high-power wiring harness: the input and output interface wiring connections in a reasonably confined space ensure the power supply capacity and performance safety; the signal anti-interference is achieved, the processing is easy to implement, and it has a better processing technology method. The wiring harness size is reasonable and meets the overall wiring requirements, which greatly reduces the production labor cost and material cost; the wiring harness reduces the number of inventory component codes, effectively improves the material turnover rate, simplifies the production and assembly process, and also improves the overall product quality warehousing qualification rate.

[0041] In order to more clearly demonstrate the technical solution and technical effects provided by the present invention, the embodiments of the present invention are described in detail with specific embodiments below.

[0042] Example 1

[0043] like Figure 1 , Figure 2 As shown:

[0044] According to the requirements of the wiring harness technical solution, the wiring harness dimensions, material configuration and processing steps are determined:

[0045] The module wiring harness provides two sets of 380V AC power supplies with a power of 30KW. The BVR wire has a cross-sectional area of ​​2.5mm2 and a rated voltage of 450V / 750V. The color of the protective ground wire insulation layer (PE) is green and yellow, the color of the neutral wire insulation layer (N) is light blue, the color of the phase wire insulation layer L1 is yellow, L2 is green, and L3 is red.

[0046] The wires are cut reasonably according to the wiring path, and the total length of the wire cutting is left with redundancy. The wire stripping length requirement is 6mm (-0.1mm∽+0.2mm). The quality is controlled by the outsourcing factory, and the pressure, speed, and incision depth of the equipment must be reasonably set.

[0047] One end of the harness has 7 FDFN2-250 terminals, and the other end has 6 C45-6 terminals and an OT2.5-4 cold-pressed terminal (heat shrink tube sheath). Terminal crimping is an important process to ensure that the wire terminal pull-off force is greater than 240N, ensuring reliable contact performance and long service life. (The first piece of the harness must be confirmed and checked with a 1000N tensile tester)

[0048] The wire harness jacket has 0.15mm copper wire and 18mm width tinned braided shielded copper mesh, with a coverage rate of ≥85%. It has high thermal conductivity, effectively improves anti-interference ability, obtains stable output power supply, prevents low-frequency interference, transfer impedance and shielding attenuation, and the shielding effect can reach ≥60dB. Both ends of the wire harness shielding mesh are grounded, one end taps 30mm, the other end taps 40mm, and are crimped with OT5-4 cold-pressed terminals respectively, and covered with heat shrink tubes.

[0049] Because the space used is 7.5mm wide, the thickness of the harness must be less than 7.5mm. Therefore, the 7 harnesses in the shielding mesh cannot cross or overlap, and the main body of the harness must be arranged in a single row of flat sheets, and the thickness after adding the shielding sheath is about 6.8mm.

[0050] The flat shape is solidified, and the separation segment glue reinforcement scheme is adopted, and auxiliary materials such as ZR706 dealcoholized bonding silicone, heat shrink tubing, and insulating tape are used. ZR706 silicone is a neutral sealing material that absorbs moisture in the air and solidifies at room temperature. It has good bonding and sealing properties for wires, excellent electrical insulation properties, anti-corona, and stable mechanical and electrical properties at -60∽+260℃, and can be used under harsh conditions.

[0051] In order to more effectively suppress electromagnetic interference, prevent magnetic leakage, and ensure that the voltage signal passes smoothly, the magnetic ring is located close to the input interface of the three-phase filter board, and 7 FDFN2-250 (female) terminal ends smoothly pass through 3 RH14*15*9 amorphous magnetic rings.

[0052] Design the appropriate harness length according to the wiring distance, and use high temperature tape and insulating tape to assist in reinforcing the shielding sleeve of the protective harness, so that it is neat and firm without interference. During the voltage resistance test, the modular harness has no flying fox, corona and breakdown, and the leakage current is ≤10mA.

[0053] The new modular structure of the wiring harness reduces redundant wiring as a whole and meets the needs of diversified models of the whole machine. The process is easy to implement and the process connection is reasonable and tight. It is suitable for outsourcing processing, reduces material management costs, and meets the required transportation conditions.

[0054] This modular new structure wiring harness meets the narrow space requirements of the equipment's power supply system. It has strong electromagnetic compatibility and anti-interference compatibility, good practicality and safety, simple and convenient operation, saves work hours, greatly improves production efficiency, reduces product manufacturing costs, and improves the overall product quality pass rate. It has now been quoted and promoted in batches.

[0055] Table 1: Modular new structure wiring harness material matching table

[0056] Serial number Material Name Specifications quantity 1 Single core multi-strand flame retardant national standard soft wire <![CDATA[ZR-BVR2.5mm 2 450V / 750V Yellow]]> 1860mm 2 Single core multi-strand flame retardant national standard soft wire <![CDATA[ZR-BVR2.5mm 2 450V / 750V Green]]> 1860mm 3 Single core multi-strand flame retardant national standard switching line <![CDATA[ZR-BVR2.5mm 2 450V / 750V Red]]> 1860mm 4 Single core multi-strand flame retardant national standard soft wire <![CDATA[ZR-BVR2.5mm 2 450V / 750V Yellow-green]]> 980mm 5 Terminal plug FDFN2-250(female) 7 6 Terminal plug C45-6 (heat shrink tube plastic sealing) 3 7 Cold pressed terminal OT2.5-4 1 8 Cold pressed terminal OT5-4 2 9 Heat shrink tubing Φ5 Black Length about 20~30mm 6 segments 10 Heat shrink tubing Φ20 Black Length about 70mm 2nd paragraph 11 Tinned copper shielding mesh Copper wire 0.15mm width 18mm or 20mm 840mm 12 PET high temperature tape Width 14mm Golden yellow 20cm 13 Heat shrink tubing Suitable for black, length about 10mm to 15mm 10 14 Silicone Rubber ZR706 Silicone transparent 5g 15 Nano amorphous magnetic ring 28x11x12.5mm\Model size (2610) 3

[0057] Table 2: Modular new structure wiring harness processing card

[0058] Serial number Material Name Specifications quantity 1 Single core multi-strand flame retardant national standard soft wire <![CDATA[ZR-BVR2.5mm 2 450V / 750V Yellow]]> 1860mm 2 Single core multi-strand flame retardant national standard soft wire <![CDATA[ZR-BVR2.5mm 2 450V / 750V Green]]> 1860mm 3 Single core multi-strand flame retardant national standard soft wire <![CDATA[ZR-BVR2.5mm 2 450V / 750V Red]]> 1860mm 4 Single core multi-strand flame retardant national standard switching line <![CDATA[ZR-BVR2.5mm 2 450V / 750V Yellow-green]]> 980mm 5 Terminal plug FDFN2-250(female) 7 6 Terminal plug C45-6 (heat shrink tube plastic sealing) 3 7 Cold pressed terminal OT2.5-4 1 8 Cold pressed terminal OT5-4 2 9 Heat shrink tubing Φ5 Black Length about 20~30mm 6 segments 10 Heat shrink tubing Φ20 Black Length about 70mm 2nd paragraph 11 Tinned copper shielding mesh Copper wire 0.15mm width 18mm or 20mm 840mm 12 PET high temperature tape Width 14mm Golden yellow 20cm 13 Heat shrink tubing Suitable for black, length about 10mm to 15mm 10 14 Silicone Rubber ZR706 Silicone transparent 5g 15 Nano amorphous magnetic ring 28x14x12.5mm\Model size (2610) 3

[0059] The above is only a preferred specific implementation of the utility model, but the protection scope of the utility model is not limited thereto. Any changes or substitutions that can be easily thought of by any technician familiar with the technical field within the technical scope disclosed in the utility model 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. The information disclosed in the background technology section of this article is only intended to deepen the understanding of the overall background technology of the utility model, and should not be regarded as an admission or in any form that the information constitutes prior art known to those skilled in the art.

Claims

1. A modular new structure power supply high power harness, characterized in that: Select BVR wire with cross-sectional area of ​​2.5mm 2 , cutting wires according to the wiring path, leaving redundancy in the total length of wire cutting, and the wire stripping length is 6mm, forming a modular wiring harness; One end of the wiring harness has seven FDFN2-250 terminals; the other end has six C45-6 terminals and an OT2.5-4 cold-pressed terminal, which is covered with a heat shrink tube.

2. The modular new structure power supply high power harness according to claim 1 is characterized in that: The harness jacket has a tinned braided shielded copper mesh with a copper wire of 0.15mm and a width of 18mm. Both ends of the shielded copper mesh are grounded, one end has a tap of 30mm, and the other end has a tap of 40mm. They are crimped with OT5-4 cold-pressed terminals and covered with heat shrink tubing.

3. The modular new structure power supply high power harness according to claim 2 is characterized in that: The 7 wire harnesses in the shielded copper mesh cannot cross or overlap. The main body of the wire harness is arranged in a single row of flat sheets, and the thickness of the shielding sheath is 6.8mm.

4. The modular new structure power supply high power harness according to claim 3 is characterized in that: The shielded copper mesh is reinforced by glue spotting at the separation section, using ZR706 dealcoholized bonding silicone, and high-temperature tape and insulating tape to assist in reinforcing the protective wiring harness and heat shrink tube to form a solidified flat shape structure.

5. The modular new structure power supply high power harness according to claim 4 is characterized in that: The seven FDFN2-250 terminal ends pass through three RH14*15*9 amorphous magnetic rings, and the magnetic rings are located close to the input interface of the three-phase filter board.

6. The modular new structure power supply high power harness according to any one of claims 1 to 5, characterized in that: The wiring harness provides two sets of 380V AC power, the power is 30KW, and the rated voltage is 450V / 750V; The color of the protective ground wire insulation layer PE is green and yellow, the color of the neutral wire insulation layer N is light blue, the color of the phase wire insulation layer L1 is yellow, L2 is green, and L3 is red.

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