A high-voltage wire harness real vehicle simulation vibration test bench device

Abstract

The utility model relates to vehicle simulation test technical field, concretely relates to a high pressure wire harness real vehicle simulation vibration test bench device. Include: vibration table, for fixing the measured high pressure wire harness and to high pressure wire harness exert vibration excitation, wire harness tool, for fixing high pressure wire harness and its high pressure connector socket with real vehicle installation attitude, fixed bench, independently with vibration table setting, for supporting the non -vibration section of wire harness tool, power cabinet, with high pressure cable and high pressure wire harness series composition test loop, for to high pressure wire harness output current, multichannel temperature collection appearance, for in the vibration process real -time collection terminal temperature rise, instantaneous break instrument, for real -time monitoring interlock loop's current continuity and record instantaneous break event, and fastener, for realizing the rigid connection between wire harness and wire harness tool, wire harness tool and vibration table and fixed bench. This technical scheme can simulate the real state of high pressure wire harness in actual operation process.

Description

Technical Field

[0001] This utility model relates to the field of vehicle simulation testing technology, specifically to a high-voltage wiring harness vehicle-based vibration simulation test bench device. Background Technology

[0002] As a key component of electric vehicle power transmission, the high-voltage wiring harness is responsible for transmitting electrical energy between core high-voltage components such as the battery pack, motor controller, and charger. Its working condition directly affects the vehicle's operational safety and service life. During actual driving, the electric vehicle body is continuously subjected to a combination of vibrations caused by uneven road surfaces, changes in vehicle speed, engine operation, and other external stimuli. This vibration environment can have a long-term impact on the high-voltage wiring harness and its connection structure.

[0003] Prolonged vibration can easily lead to structural damage in high-voltage wiring harnesses, such as fatigue wear, wire insulation cracking, and conductor shielding wire breakage. It can also cause problems like loose connector fixing screws and poor terminal contact, resulting in increased contact resistance, excessive localized temperature rise, and in severe cases, terminal burn-out and interlock circuit interruption, directly threatening the driving safety of electric vehicles. Therefore, before mass production of high-voltage wiring harnesses, reliability testing simulating real-vehicle vibration environments is essential to comprehensively evaluate their structural stability, electrical performance continuity, and thermal safety under vibration conditions, ensuring they meet the requirements for real-vehicle use.

[0004] Most existing tests use a simple fixing method where the wiring harness is directly fixed to a fixture plate, and then the fixture plate is installed on a vibration table. This fixing method fails to reproduce the installation posture, support method and stress state of the high-voltage wiring harness in a real vehicle. It lacks effective simulation of the real vehicle installation environment, resulting in a large deviation between the test environment and the actual working conditions. It is difficult to truly reflect the failure mode of the high-voltage wiring harness under the vibration of a real vehicle and cannot accurately assess its actual reliability. Utility Model Content

[0005] The purpose of this utility model is to propose a high-voltage wiring harness vehicle-based vibration simulation test bench device, which can simulate the real state of the high-voltage wiring harness during actual operation.

[0006] To achieve the above objectives, this disclosure provides a high-voltage wiring harness vehicle-based simulated vibration test bench device, comprising: A vibration table is used to fix the high-voltage line harness under test and apply vibration excitation to the high-voltage line harness. Wiring harness fixture, including mounting plate, fastening components and height-adjustable wing plate, is used to fix high-voltage wiring harness and its high-voltage connector socket in a vehicle mounting posture; A fixed frame, set independently of the vibration table, is used to support the non-vibration section of the wire harness fixture; The power cabinet is connected in series with the high-voltage harness via high-voltage cables to form a test circuit, which is used to output current to the high-voltage harness. A multi-channel temperature acquisition instrument, with its thermocouple fixed in the high-voltage harness terminal monitoring area, is used to collect the terminal temperature rise in real time during vibration. The instantaneous interruption device is connected to the interlock circuit of the high-voltage line harness and is used to monitor the current continuity of the interlock circuit and record instantaneous interruption events in real time. And fasteners, used to achieve rigid connections between wire harnesses and wire harness fixtures, and between wire harness fixtures and vibration tables and fixed frames.

[0007] The beneficial effects of the above solution are as follows: This wiring harness fixture, through the combined design of mounting plate, fastening components and height-adjustable wing plate, can completely simulate the installation posture of high-voltage wiring harness in a real vehicle, including the wiring harness routing, connector socket fixing angle, and relative positional relationship with surrounding components. It solves the problem of test results being out of sync with the actual vehicle operation state caused by the distortion of the traditional bench installation posture, and makes the force and deformation of the wiring harness under vibration excitation conform to the actual use scenario.

[0008] The fixed stand is set up independently of the vibration table and only supports the non-vibration section of the wire harness fixture. This ensures that the vibration excitation applied by the vibration table to the wire harness under test is pure and interference-free, and also reproduces the real force pattern of the actual vehicle, which is partially fixed and partially vibrates with the vehicle body. This avoids test deviations caused by overall vibration or unstable fixing.

[0009] The multi-channel temperature acquisition instrument uses thermocouples to monitor the high-voltage harness terminal monitoring area at fixed points, capturing temperature rise changes during vibration in real time. It can directly reflect the contact reliability of the terminal connection (such as increased contact resistance and abnormal temperature rise caused by loosening), avoiding the shortcomings of traditional "static temperature measurement" which cannot reflect the temperature rise risk under vibration conditions.

[0010] The instantaneous interruption device is linked with the interlocking circuit in real time to accurately monitor the continuity of current and record instantaneous interruption events. It can directly locate problems such as loose terminals and poor contact caused by vibration, and provide quantitative data for the stability verification of the interlocking circuit.

[0011] The quantitative data obtained through testing, such as temperature rise curves, transient interruption frequency, and structural damage, can directly pinpoint weak points in the design of high-voltage harnesses (such as unreasonable terminal selection, insufficient fixing points, and poor vibration resistance of the shielding layer structure). This provides a precise basis for product structure optimization (such as optimizing terminal contact methods, increasing fixing points, and strengthening shielding layer protection), helping to improve the vibration resistance design level of high-voltage harnesses.

[0012] As a feasible preferred solution, the mounting plate of the wiring harness tooling is provided with positioning grooves and threaded holes that are consistent with the contour of the high-voltage connector socket of the actual vehicle, so that the high-voltage connector can be rigidly fixed with the torque specified in the actual vehicle, thereby replicating the boundary constraint conditions of the actual vehicle.

[0013] As a feasible preferred solution, the wing plate of the wire harness tooling has several levels of adjustment holes in the vertical direction. By changing the bolt connection position between the wing plate and the mounting plate, the height of the wire harness in the vertical direction can be adjusted.

[0014] As a feasible preferred solution, the mounting plate of the wiring harness tooling is provided with a positioning groove and threaded hole that are consistent with the contour of the high-voltage connector socket of the actual vehicle, so that the high-voltage connector can be rigidly fixed with the torque specified in the actual vehicle.

[0015] As a feasible preferred embodiment, the mounting plate surface of the wire harness fixture is inlaid with copper conductive blocks, and the connector sockets of the high-voltage wire harness are connected in series via the copper conductive blocks.

[0016] As a feasible preferred embodiment, the thermocouple uses soft paper as the bonding medium and is fixed with glue.

[0017] As a feasible preferred option, the fixed frame and the vibration table are isolated by vibration damping pads. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of a high-voltage wiring harness vehicle-based vibration simulation test bench device.

[0019] Figure descriptions: 1-Power cabinet; 2-Instantaneous interruption device; 3-Multi-channel temperature acquisition instrument; 4-Vibration table; 5-Fixed frame; 6-Wire harness support bracket; 7-Wire harness fixture. Detailed Implementation

[0020] To make the technical solution and advantages of this application clearer, the technical solution of this utility model will be further described in detail below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are only some embodiments of this utility model, and are only used to explain this application, not to limit it. It should be noted that the technical features or combinations of technical features described in the following embodiments should not be considered isolated; they can be combined with each other to achieve better technical effects. The same reference numerals appearing in the accompanying drawings of the following embodiments represent the same features or components, and can be applied to different embodiments.

[0021] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "set" and "connection" should be interpreted broadly. For example, it can be a fixed connection, a detachable connection, or an integrated connection; it can be a mechanical connection (including various forms of mechanical connection, such as couplings or gear pairs), or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, or it can be a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0022] Furthermore, unless otherwise defined, the technical or scientific terms used in this description shall have the ordinary meaning as understood by one of ordinary skill in the art to which this invention pertains.

[0023] The present invention will now be described in further detail with reference to the accompanying drawings: Reference Figure 1 A high-voltage wiring harness vehicle-based vibration simulation test bench device mainly includes a vibration table 4, wiring harness fixture 7, power supply cabinet 1, multi-channel temperature acquisition instrument 3, instantaneous interruption instrument 2, and fasteners.

[0024] The connection and positional relationships between the components are as follows: The vibration table 4 is the core component of the entire test bench. It must be at least 3 tons in weight to hold the sample and provide specified vibration conditions. The vibration table 4 is computer-controlled and can simulate various vibrations experienced by the high-voltage wiring harness during actual operation.

[0025] In this embodiment, the vibration table 4 is model ES-30 / LT0808, with a frequency range of 2 to 2800 Hz and a maximum acceleration of 100G.

[0026] The vibration table 4 has a built-in storage module containing a road spectrum database. It can call up random vibration spectra or sinusoidal sweep spectra collected from real vehicles to realize real driving conditions.

[0027] The wiring harness fixture 7 consists of mounting plates, fastening components, and wing plates of various structures. The fastening components are detachably connected to the wing plates, and by adjusting the height and structure of the wing plates, the actual vehicle installation state of the wiring harness can be simulated. The wiring harness fixture 7 is designed with a mounting and fixing structure for the high-voltage connector socket on the high-voltage wiring harness, used to fix the wiring harness. Part of the wiring harness fixture 7 is mounted on the vibration table 4, and part is mounted on the fixed frame 5 outside the vibration table 4 to simulate the vibration and non-vibration parts of the wiring harness in a real vehicle.

[0028] The fixed frame 5 and the vibration table 4 are isolated by vibration damping pads to prevent vibration coupling and ensure that the non-vibration section is in a quasi-static environment.

[0029] The mounting plate of the wiring harness fixture 7 is provided with a positioning groove and a threaded hole that are consistent with the outline of the high-voltage connector socket of the actual vehicle, so that the high-voltage connector can be rigidly fixed with the torque specified by the actual vehicle, thereby replicating the boundary constraint conditions of the actual vehicle.

[0030] The wing plate of the wiring harness fixture 7 has several levels of adjustment holes in the vertical direction. By changing the bolt connection position between the wing plate and the mounting plate, the height of the wiring harness in the vertical direction can be adjusted to meet the simulation requirements of the ground clearance of different vehicle chassis.

[0031] The mounting plate of the wire harness fixture 7 is inlaid with copper conductive blocks, and each connector socket of the high-voltage wire harness is connected in series through the copper conductive blocks to form a low-impedance high-current test circuit.

[0032] Power cabinet 1 is connected to the high-voltage wiring harness, providing the specified high current to the harness. The high-voltage wiring harness circuits are connected in series via high-voltage cables to form a test circuit.

[0033] The multi-channel temperature acquisition instrument 3 is used to collect the temperature rise at the terminals of the high-voltage harness during vibration. The thermocouple is tightly attached to the terminal monitoring area using soft paper as a medium and filled with adhesive to ensure that the temperature rise will not be abnormal due to loosening of the adhesive during vibration.

[0034] In this embodiment, the multi-channel temperature data acquisition instrument is model LR8450-01, and the acquired temperature parameters are: thermocouple (K: -20℃~200℃), temperature accuracy ±1.5℃.

[0035] Interrupt current meter 2 is used to monitor the continuity of current in non-current-carrying power circuits and interlocking circuits. Interrupt current meter 2 is connected to the interlocking terminals to monitor the interruption status of each wire harness interlocking circuit in real time.

[0036] In this embodiment, the instantaneous disconnection meter is model NMS10, and the instantaneous disconnection detection range is 0.1us~99.9us.

[0037] Fasteners, including bolts and nuts, are used to secure the wire harness to the tooling, between tooling components, and between the tooling and the fixed frame 5, ensuring a stable and reliable connection between the components.

[0038] The steps for using this device include: Wiring harness installation: Secure the connector and wiring harness to the mounting plate of wiring harness fixture 7 using bolts to the specified torque. Ensure the wiring harness installation method matches the actual vehicle installation.

[0039] Fixture fixing: Fix part of the wire harness fixture 7, on the vibration table 4, and part of it on the fixed frame 5 outside the vibration table 4.

[0040] By adjusting the height and structure of the wing plate, the wiring harness fixture 7 can simulate the installation state in a real vehicle.

[0041] Series Connection and Monitoring Setup: Connect one end of the connector on the vibration table 4 in series with a copper block to form a test circuit. Attach thermocouples to the terminal monitoring area and use a multi-channel temperature acquisition instrument 3 to monitor key temperature information. Simultaneously, connect the instantaneous interruption device 2 to the interlock terminal to monitor the instantaneous interruption of the interlock circuit.

[0042] Vibration Test: Start vibration table 4 and vibrate according to a specific spectrum. During vibration, collect temperature data of the wire harness terminals in real time and observe any momentary interruptions. If wire harness breakage, abnormal temperature, or unstable current occurs, immediately stop the test and check the integrity of the wire harness and connectors.

[0043] Post-test inspection: After the test, the product's appearance, insulation resistance, withstand voltage, wire stripping, etc., are inspected to verify the product's reliability.

[0044] The above content is merely an embodiment of this utility model. Commonly known structures and characteristics are not described in detail here. Those skilled in the art are aware of all common technical knowledge in the field prior to the application date or priority date, are aware of all existing technologies in that field, and have the ability to apply conventional experimental methods prior to that date. Those skilled in the art can improve and implement this solution based on the guidance provided in this application and their own capabilities. Typical known structures or methods should not be obstacles for those skilled in the art to implement this application. It should be noted that those skilled in the art can make several modifications and improvements without departing from the structure of this utility model. These should also be considered within the scope of protection of this utility model, and will not affect the effectiveness of the implementation of this utility model or the practicality of the patent. The scope of protection claimed in this application should be determined by the content of its claims, and the specific embodiments described in the specification can be used to interpret the content of the claims.

Claims

1. A high-voltage wiring harness vehicle-based simulated vibration testing bench device, characterized in that: include: A vibration table is used to fix the high-voltage line harness under test and apply vibration excitation to the high-voltage line harness. Wiring harness fixture, including mounting plate, fastening components and height-adjustable wing plate, is used to fix high-voltage wiring harness and its high-voltage connector socket in a vehicle mounting posture; A fixed frame, set independently of the vibration table, is used to support the non-vibration section of the wire harness fixture; The power cabinet is connected in series with the high-voltage harness via high-voltage cables to form a test circuit, which is used to output current to the high-voltage harness. A multi-channel temperature acquisition instrument, with its thermocouple fixed in the high-voltage harness terminal monitoring area, is used to collect the terminal temperature rise in real time during vibration. The instantaneous interruption device is connected to the interlock circuit of the high-voltage line harness and is used to monitor the current continuity of the interlock circuit and record instantaneous interruption events in real time. And fasteners, used to achieve rigid connections between wire harnesses and wire harness fixtures, and between wire harness fixtures and vibration tables and fixed frames.

2. The high-voltage wiring harness vehicle-based vibration simulation test bench device according to claim 1, characterized in that: The mounting plate of the wiring harness fixture is provided with a positioning groove and threaded hole that are consistent with the outline of the high-voltage connector socket of the actual vehicle, so that the high-voltage connector can be rigidly fixed with the torque specified by the actual vehicle, thereby replicating the boundary constraint conditions of the actual vehicle.

3. The high-voltage wiring harness vehicle-based vibration simulation test bench device according to claim 1, characterized in that: The wing plate of the wire harness fixture has several levels of adjustment holes along the vertical direction. By changing the bolt connection position between the wing plate and the mounting plate, the height of the wire harness in the vertical direction can be adjusted.

4. The high-voltage wiring harness vehicle-based vibration simulation test bench device according to claim 1, characterized in that: The mounting plate of the wiring harness fixture is provided with a positioning groove and threaded hole that are consistent with the outline of the high-voltage connector socket of the actual vehicle, so that the high-voltage connector can be rigidly fixed with the torque specified in the actual vehicle.

5. The high-voltage wiring harness vehicle-based vibration simulation test bench device according to claim 1, characterized in that: The mounting plate of the wire harness fixture is inlaid with copper conductive blocks, and each connector socket of the high-voltage wire harness is connected in series through the copper conductive blocks.

6. The high-voltage wiring harness vehicle-based vibration simulation test bench device according to claim 1, characterized in that: The thermocouple is bonded with soft paper and fixed with glue.

7. The high-voltage wiring harness vehicle-based vibration simulation test bench device according to claim 1, characterized in that: The fixed frame and the vibration table are isolated by vibration damping pads.

8. The high-voltage wiring harness vehicle-based vibration simulation test bench device according to claim 1, characterized in that: The vibration is equipped with a built-in storage module, which stores a road spectrum database.

9. The high-voltage wiring harness vehicle-based vibration simulation test bench device according to claim 1, characterized in that: Fasteners include bolts and nuts.

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