Vehicle-mounted high-voltage wire harness integrated filter fixing device

Abstract

The utility model relates to the technical field of wiring harness fixing device provides a kind of vehicle high-voltage wiring harness integrated formula filtering fixing device, comprising: ribbon body;Magnetic ring, integrally set in the side of ribbon body towards high-voltage wiring harness, and in the use state of ribbon body, magnetic ring encloses closed ring body.The utility model provides a kind of vehicle high-voltage wiring harness integrated formula filtering fixing device, not only magnetic ring is conducted to common-mode noise current by its high magnetic guide characteristic, to effectively attenuate electromagnetic interference along high-voltage wiring harness propagation;And magnetic ring forms distributed inductance on wiring harness, changes the high-frequency transmission characteristic of high-voltage wiring harness, destroys original resonance condition, inhibits the voltage amplification phenomenon caused by length and noise wavelength matching;While ribbon body can realize the automatic fastening after bundling, realizes the mechanical fixing of high-voltage wiring harness.

Description

Technical Field

[0001] This utility model relates to the technical field of wire harness fixing devices, and in particular to an integrated filter fixing device for vehicle-mounted high-voltage wire harnesses. Background Technology

[0002] In the high-voltage electric drive system of new energy vehicles, the high-voltage wiring harness (generally 600V / 800V level) at the inverter output end is a critical path for electromagnetic interference (EMI) conduction.

[0003] In existing technologies, most fixing devices are nylon cable ties, which only provide mechanical fixation and lack electromagnetic interference suppression capabilities. If an additional magnetic ring is added for filtering, space must be reserved for straight installation, making it difficult to accommodate the curved layout requirements of the wiring harness in the chassis area. Moreover, the LC filter inside the inverter has limited attenuation effect on ultra-high frequency noise exceeding 10MHz (such as 200kHz–300MHz harmonics generated during the switching process of SiC / GaN power devices), causing residual noise to be conducted to the motor windings via the high-voltage wiring harness, resulting in increased torque ripple (typically exceeding 5%). At the same time, the wiring harness resonates because its electrical length is comparable to the noise wavelength (e.g., approximately 1m for 300MHz), causing the noise voltage to be amplified by 3–5 times.

[0004] Therefore, how to provide an integrated filter fixing device for vehicle-mounted high-voltage wiring harnesses that combines mechanical fixing and electromagnetic filtering is a technical problem that urgently needs to be solved by those skilled in the art. Utility Model Content

[0005] This utility model provides an integrated filter fixing device for vehicle-mounted high-voltage wiring harnesses, which solves the defects of existing technologies that only provide mechanical fixing and do not have electromagnetic interference suppression capabilities, and realizes the dual functions of mechanical fixing and electromagnetic filtering in one device.

[0006] This utility model provides an integrated filter fixing device for vehicle-mounted high-voltage wiring harnesses, comprising: Tie body; A magnetic ring is integrally disposed on the side of the cable tie body facing the high-voltage wire harness, and in the use state of the cable tie body, the magnetic ring forms a closed ring.

[0007] According to the present invention, an integrated filter fixing device for vehicle-mounted high-voltage wiring harnesses is provided, wherein the cable tie body comprises: The outer casing has a binding channel with ratchet teeth. The rack structure has one end connected to the outer shell and the other end being a free end, and the rack structure is unidirectionally locked to the ratchet.

[0008] According to the integrated filter fixing device for vehicle-mounted high-voltage wiring harnesses provided by this utility model, the cable tie body further includes: The guide bar has its first end integrally disposed at the free end of the rack structure, and the width of the guide bar gradually decreases in the direction away from the guide bar.

[0009] According to the present invention, an integrated filter fixing device for vehicle-mounted high-voltage wiring harness is provided, wherein the cable tie body includes a PPS cable tie.

[0010] According to the present invention, an integrated filter fixing device for vehicle-mounted high-voltage wiring harness is provided, wherein the magnetic ring is formed by winding nanocrystalline ribbon, and the outer layer of the magnetic ring is injection molded and encapsulated inside the cable tie body.

[0011] According to the present invention, an integrated filter fixing device for vehicle-mounted high-voltage wiring harness is provided, wherein the thickness of the nanocrystalline ribbon is 20-30μm.

[0012] According to the present invention, an integrated filter fixing device for vehicle-mounted high-voltage wiring harness is provided, wherein the inner surface of the rack structure is provided with a plurality of anti-slip protrusions for increasing the friction with the high-voltage wiring harness.

[0013] According to the present invention, an integrated filter fixing device for vehicle-mounted high-voltage wiring harness is provided, wherein the magnetic ring is covered with a protective plastic shell before injection molding.

[0014] According to the present invention, an integrated filter fixing device for vehicle-mounted high-voltage wiring harnesses is provided, wherein the cross-section of the guide strip is trapezoidal or triangular.

[0015] According to the present invention, an integrated filter fixing device for vehicle-mounted high-voltage wiring harness is provided, wherein the teeth at the end of the rack structure are spaced apart from the end of the rack structure.

[0016] The integrated filtering and fixing device for vehicle-mounted high-voltage wiring harnesses provided by this utility model uses a magnetic ring integrally set on the side of the cable tie body facing the high-voltage wiring harness. When the cable tie body is in use, the magnetic ring forms a closed loop. On the one hand, the magnetic ring, with its high magnetic permeability, conducts common-mode noise current, thereby effectively attenuating electromagnetic interference propagating along the high-voltage wiring harness. On the other hand, the magnetic ring forms a distributed inductance on the wiring harness, changing the high-frequency transmission characteristics of the high-voltage wiring harness, disrupting the original resonance conditions, and suppressing the voltage amplification phenomenon caused by the matching of length and noise wavelength. At the same time, the cable tie body can achieve automatic fastening after bundling, realizing the mechanical fixing of the high-voltage wiring harness. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0018] Figure 1 This is a structural schematic diagram of the vehicle-mounted high-voltage wiring harness integrated filter fixing device provided by this utility model.

[0019] Figure 2 This is a structural diagram of the vehicle-mounted high-voltage wiring harness integrated filter fixing device provided by this utility model in use.

[0020] Figure 3 This is a top view of the vehicle-mounted high-voltage wiring harness integrated filter fixing device provided by this utility model in its usage state.

[0021] Figure 4 yes Figure 3 Sectional view of AA.

[0022] Figure 5 This is a schematic diagram of the installation status of the vehicle-mounted high-voltage wiring harness integrated filter fixing device provided by this utility model.

[0023] Figure label: 1. Cable tie body; 2. Magnetic ring; 11. Outer shell; 12. Rack and pinion structure; 13. Guide bar. Detailed Implementation

[0024] To make the objectives, technical solutions, and advantages of this utility model clearer, the technical solutions of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0025] The following is combined with Figures 1-5 The present invention describes an integrated filter fixing device for vehicle-mounted high-voltage wiring harnesses, comprising a cable tie body 1 and a magnetic ring.

[0026] Specifically, the magnetic ring 2 is integrally disposed on the side of the cable tie body 1 facing the high-voltage wire harness, and when the cable tie body 1 is in use, the magnetic ring 2 forms a closed ring. On the one hand, the magnetic ring 2, with its high magnetic permeability, conducts common-mode noise current, thereby effectively attenuating electromagnetic interference propagating along the high-voltage wire harness. On the other hand, the magnetic ring 2 forms a distributed inductance on the wire harness, changing the high-frequency transmission characteristics of the high-voltage wire harness, disrupting the original resonance conditions, and suppressing the voltage amplification phenomenon caused by the matching of length and noise wavelength. It has a wideband noise suppression capability of 200kHz–300MHz, which can effectively eliminate the wire harness resonance effect and attenuate the residual harmonic voltage to less than 1% torque ripple, improving the control accuracy and stability of the electric drive system. At the same time, the cable tie body 1 can realize automatic fastening after bundling, realizing the mechanical fixation of the high-voltage wire harness, integrating mechanical fixation and EMI filtering functions into one, eliminating the need for an external magnetic ring 2, significantly saving layout space, and being more adaptable to curved pipeline layouts, reducing space occupation by more than 50%.

[0027] Moreover, it overcomes the performance degradation problem of traditional plastic cable ties and ferrite magnetic rings under high temperature and dynamic environments. This nanocrystalline material has extremely high initial permeability (up to 20,000 or more at 10 kHz), ensuring excellent noise suppression capability in the low frequency range (such as 200 kHz), effectively filtering the frequency up to 300 MHz, and possessing excellent high frequency noise suppression capability.

[0028] In one feasible embodiment of this utility model, the cable tie body 1 includes a housing 11 and a rack structure 12. The housing 11 has a binding channel with ratchet teeth. One end of the rack structure 12 is connected to the housing 11, and the other end is a free end, allowing the operator to easily wrap it around and pass it through the high-voltage wire harness that needs to be fixed. This adapts to the bundling requirements of wire harnesses of different diameters and has good versatility. In use, the rack structure 12 extends into the binding channel and locks unidirectionally with the ratchet teeth. Through the easy-to-enter and difficult-to-remove locking mechanism, automatic fastening after bundling is achieved. Even under bumpy and vibrating conditions during vehicle operation, it can provide a durable and stable clamping force, thereby realizing automated fastening and long-term reliable fixation of high-voltage wire harnesses.

[0029] In a feasible embodiment of this utility model, the cable tie body 1 further includes a guide strip 13. The first end of the guide strip 13 is integrally disposed on the free end of the rack structure 12, and the width of the guide strip 13 gradually decreases in the direction away from the guide strip, forming a tapered head that gradually narrows. This greatly facilitates the operator in inserting the rack structure 12 into the binding channel of the outer shell 11. The guide strip 13 plays a precise guiding role, making the insertion action smoother and faster. Especially in the case of limited space or blind operation on the automotive assembly line, it can significantly reduce alignment time and reduce installation difficulty, thereby effectively improving assembly efficiency and ease of operation.

[0030] In one feasible embodiment of this utility model, the cable tie body 1 includes a PPS cable tie. PPS material is suitable for harsh environments such as high temperature and corrosion resistance. Its operating temperature range is -40℃ to 180℃, ensuring stable physical properties regardless of the low temperatures of winter in cold regions or areas with high-temperature components such as engines and inverters. This effectively avoids the risk of softening and deformation caused by drastic temperature changes in traditional plastics. Simultaneously, its tensile strength is not less than 120 MPa, ensuring that the cable tie body 1 possesses excellent mechanical strength, providing strong and durable locking force sufficient to securely fix heavy high-voltage wiring harnesses and resist vibrations and impacts during vehicle operation, thereby ensuring the long-term safety and reliability of the wiring harness. Therefore, the excellent high-temperature stability and mechanical strength of PPS material, combined with its corrosion resistance, ensure the functional integrity and structural reliability of the integrated device throughout the entire vehicle lifecycle.

[0031] In one feasible embodiment of this invention, the magnetic ring 2 is formed by winding nanocrystalline ribbon. Compared with traditional ferrite magnetic rings, nanocrystalline materials have higher initial permeability and saturation magnetic flux density, enabling them to provide strong high-frequency noise suppression capabilities within a compact volume. Furthermore, they are less prone to magnetic saturation when facing large current fluctuations in high-voltage systems, thus ensuring the continuous effectiveness of the filtering function under various operating conditions. The outer layer of the magnetic ring 2 is injection molded inside the cable tie body 1, providing comprehensive mechanical protection for the physically fragile nanocrystalline ribbon, enabling it to withstand vibration, impact, and harsh environmental corrosion, ensuring its long-term reliability. It also allows the filtering element and the fixing element to be perfectly integrated into a single part, greatly simplifying the installation process and reducing assembly error rates. This method of blocking the common-mode current loop with a high-impedance nanocrystalline magnetic ring strictly controls the radiated emission value within the limits of GB / T 18655 standard, improving the overall vehicle EMC performance.

[0032] In one feasible embodiment of this invention, the thickness of the nanocrystalline ribbon is 20-30 μm. This thickness range is a key parameter selection for achieving high-performance filtering. Specifically, a thinner ribbon can effectively suppress the eddy current effect caused by magnetic field changes at high frequencies, thereby reducing eddy current losses and ensuring that the magnetic ring maintains high permeability and high impedance characteristics in the high-frequency band up to 300 MHz. This is crucial for effectively attenuating high-frequency electromagnetic interference. Preferably, the thickness of the nanocrystalline ribbon is 25 μm. This preferred value is the optimal balance between high-frequency filtering performance and material processing feasibility. It ensures that the eddy current loss is low enough to meet the requirements of broadband noise suppression, while also taking into account the mechanical strength and production efficiency of the ribbon during the winding process, ultimately achieving an optimal combination of product performance, reliability, and manufacturing cost.

[0033] In one feasible embodiment of this utility model, the inner surface of the rack structure 12 is provided with multiple anti-slip protrusions (not shown in the figure) to increase the friction with the high-voltage wiring harness. By forming a physical fit on the contact surface, it can effectively prevent the high-voltage wiring harness from sliding axially or rotating circumferentially. Especially when the vehicle is subjected to dynamic conditions such as bumps and vibrations, these anti-slip protrusions can ensure that the device is always firmly fixed in the preset installation position, thereby ensuring that the filtering function of the magnetic ring acts on the most critical wiring harness section, while avoiding potential stress or wear on the wiring harness itself and its connectors that may be caused by wiring harness displacement or torsion, ultimately greatly improving the stability and long-term reliability of the wiring harness fixation.

[0034] In one feasible embodiment of this invention, the magnetic ring 2 is encased in a protective plastic shell before injection molding. Because the magnetic ring, made of nanocrystalline ribbon, is inherently brittle and cannot withstand the high temperature and pressure of injection molding, the pre-encased plastic shell provides a robust primary barrier, effectively resisting the direct impact and thermal stress from the molten plastic during injection molding. This prevents the magnetic ring from cracking, deforming, or experiencing magnetic degradation during molding, significantly improving the yield rate and product quality consistency in the production process. Simultaneously, the plastic shell provides a second layer of protection for the magnetic ring 2 inside the cable tie body 1, further enhancing the device's vibration and impact resistance during actual vehicle operation, ensuring the long-term stability and reliability of the magnetic ring 2's core filtering function.

[0035] In one feasible embodiment of this utility model, the cross-section of the guide strip 13 is trapezoidal or triangular. This cross-sectional shape defines a sharp or narrow front profile of the guide strip 13. When the operator inserts it into the binding channel of the housing 11, this structure acts as a wedge-like guide, automatically aligning and smoothly sliding into the entrance of the binding channel. Even if there is a slight deviation in the initial alignment, it can effectively prevent insertion failure or jamming, significantly reducing the positioning difficulty in the assembly process and further improving the convenience of installation and the overall assembly efficiency.

[0036] In one feasible embodiment of this utility model, there is a gap between the serrations at the end of the rack structure 12 and the end of the rack structure 12. This gap forms a smooth, toothless guide zone at the end of the rack structure 12, playing a crucial role in initial guidance and positioning during assembly. This ensures that the free end of the rack structure 12 smoothly and unobstructedly enters the binding channel, effectively preventing jamming caused by interference or abnormal engagement between the serrations and ratchet teeth during the initial insertion stage. Ultimately, this not only significantly improves the convenience and speed of installation operations but also ensures the reliability of the locking engagement and a high success rate.

[0037] In summary, the integrated filter and fixing device for vehicle-mounted high-voltage wiring harnesses provided by this utility model breaks through the traditional design approach of separating filtering, shielding, and fixing phases. It achieves multi-physics synergistic optimization of electromagnetic compatibility, mechanical reliability, and thermal management performance, providing a system-level, highly reliable EMI solution for high-voltage electric drive systems. Compared with traditional plastic cable ties, this utility model offers fundamental improvements in electrical performance, spatial adaptability, and environmental reliability.

[0038] In the description of the embodiments of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "connected" and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in the embodiments of this utility model according to the specific circumstances.

[0039] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "method," "specific method," or "some methods," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or method is included in at least one embodiment or method of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or method. Furthermore, the specific features, structures, materials, or characteristics described may be combined in a suitable manner in any one or more embodiments or methods. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or methods described in this specification, as well as the features of different embodiments or methods.

[0040] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and not to limit it. Although this utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this utility model.

Claims

1. An integrated filter fixing device for vehicle-mounted high-voltage wiring harnesses, characterized in that, include: Tie body (1); The magnetic ring (2) is integrally disposed on the side of the cable tie body (1) facing the high voltage wire harness, and in the use state of the cable tie body (1), the magnetic ring (2) forms a closed ring.

2. The vehicle-mounted high-voltage harness integrated filter fixing device according to claim 1, characterized in that, The cable tie body (1) includes: The outer casing (11) has a binding channel with ratchet teeth. The rack structure (12) is connected to the outer shell (11) at one end and is a free end at the other end, and the rack structure (12) is locked in one direction with the ratchet.

3. The vehicle-mounted high-voltage wiring harness integrated filter fixing device according to claim 2, characterized in that, The cable tie body (1) also includes: The guide bar (13) is integrally disposed at the free end of the rack structure (12) at its first end, and the width of the guide bar (13) gradually decreases in the direction away from the guide bar (13).

4. The vehicle-mounted high-voltage wiring harness integrated filter fixing device according to any one of claims 1-3, characterized in that, The cable tie body (1) includes a PPS cable tie body.

5. The vehicle-mounted high-voltage harness integrated filter fixing device according to claim 1, characterized in that, The magnetic ring (2) is formed by winding nanocrystalline ribbon, and the outer layer of the magnetic ring (2) is injection molded and encapsulated inside the cable tie body (1).

6. The vehicle-mounted high-voltage wiring harness integrated filter fixing device according to claim 5, characterized in that, The thickness of the nanocrystals is 20-30 μm.

7. The vehicle-mounted high-voltage wiring harness integrated filter fixing device according to claim 2, characterized in that, The inner surface of the rack structure (12) is provided with a plurality of anti-slip protrusions for increasing friction with the high voltage harness.

8. The vehicle-mounted high-voltage wiring harness integrated filter fixing device according to claim 1, characterized in that, Before injection molding, the magnetic ring (2) is covered with a protective plastic shell.

9. The vehicle-mounted high-voltage wiring harness integrated filter fixing device according to claim 3, characterized in that, The cross-section of the guide strip (13) is trapezoidal or triangular.

10. The vehicle-mounted high-voltage harness integrated filter fixing device according to claim 2, characterized in that, The teeth at the end of the rack structure (12) are spaced apart from the end of the rack structure (12).

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