Direct current harness for all-in-one controller

Abstract

The utility model relates to new energy automobile connecting wire harness technical field, concretely relates to a direct current wire harness for all -in -one controller, including first joint, cable and second joint connected in proper order, first stripping structure includes first crimping section and first shielding section who sets up in proper order from the first end to the tail end direction along the cable axial direction, and the outside of first shielding section is crimped with shielding sleeve, second stripping structure includes second crimping section and second shielding section who sets up in proper order from the tail end to the first end direction along the cable axial direction, first joint crimping is in first crimping section, and first joint is configured to connect the interface of cable and all -in -one controller, the crimping terminal of second joint crimping is in second crimping section, and the base is installed in second shielding section, and the outside of base is provided with shielding ring, and second joint is configured to connect the interface of cable and battery package unit with crimping terminal and base, improves the connection reliability, and has improved sealed protection performance and full -length shielding effect.

Description

Technical Field

[0001] This utility model relates to the field of wiring harness technology for new energy vehicles, specifically to a DC wiring harness for an all-in-one controller. Background Technology

[0002] With the rapid development of the new energy vehicle sector, all-in-one controllers have become core components in various power control systems due to their advantages such as high integration, small footprint, and low energy consumption. All-in-one controllers typically integrate multiple functional modules such as inverters, DC / DC converters, and on-board chargers. During operation, they require high-voltage, high-current transmission between these modules and between the controller and external devices via DC wiring harnesses. Therefore, the performance of the DC wiring harness directly affects the overall reliability, safety, and stability of the all-in-one controller.

[0003] Especially in scenarios where all-in-one controllers are connected to battery packs, existing crimping of terminals and cables often uses a cold-pressing process, which can easily lead to problems such as incomplete connections and over-crimping. Furthermore, the lack of effective sealing and protection at the crimping points allows moisture, dust, and other contaminants to easily seep into the crimping gaps, causing copper wires to oxidize and corrode. This not only reduces conductivity but also weakens the mechanical connection strength at the crimping point, further increasing the risk of detachment.

[0004] In addition, the large current transmitted by DC cable harnesses generates strong electromagnetic radiation. If the shielding performance is insufficient, the radiated signal will interfere with surrounding systems. At the same time, external interference may also intrude into the cable harness, affecting transmission stability. The shielding layer of existing cables does not cover the entire length of the cable harness, especially in the transition section between the terminal and the conductor. There are often cases where the shielding layer is cut off and does not extend to the terminal shell, which greatly affects the shielding performance of the cable harness. Summary of the Invention

[0005] The purpose of this invention is to provide a wiring harness structure for scenarios where an all-in-one controller is connected to a battery pack, so as to improve the connection reliability of the DC wiring harness, enhance the sealing and protection performance, and improve the overall shielding effect.

[0006] To achieve the above objectives, this utility model proposes a DC wiring harness for an all-in-one controller, comprising a first connector, a cable, and a second connector connected in sequence. The first end of the cable is provided with a first stripping structure, and the tail end of the cable is provided with a second stripping structure. The first stripping structure includes a first crimping section and a first shielding section arranged sequentially along the cable axis from the beginning to the end, and a shielding sleeve is crimped onto the outside of the first shielding section. The second stripping structure includes a second crimping section and a second shielding section arranged sequentially along the cable axis from the tail end to the head end; The first connector is crimped into the first crimp section, and the first connector is configured to connect the cable to the interface of the all-in-one controller; The second connector includes a base and a crimp terminal, the crimp terminal being crimped into a second crimp section, the base being mounted on a second shielding section, and a shielding ring being provided on the outer side of the base. The second connector is configured to connect a cable to the interface of a battery pack unit using the crimp terminal and the base.

[0007] The cable has a first stripping structure at the beginning and a second stripping structure at the end, which has a second crimping section. This ensures that the crimping terminals of the first connector and the cable, and the second connector and the cable, each have their own dedicated crimping area. This facilitates precise control of the crimping force and contact area, avoiding problems such as loose connections and over-crimping caused by chaotic crimping positions in traditional cold pressing processes. This, in turn, ensures the continuity of power transmission between the multi-function controller and the battery pack.

[0008] Furthermore, the cable's head end is tightly fitted to the first shielding section through a shielding sleeve, preventing the shielding layer from being cut off at the head end connector; the tail end, with the help of the base and the second shielding section installation, as well as the shielding ring on the outside of the base, effectively connects the shielding layer of the second shielding section with the shielding ring, covering the transition section between the terminal and the cable. This solves the problem of traditional wire harness shielding layers not covering the entire length and having shielding breaks, forming full-length electromagnetic shielding from the first connector to the second connector.

[0009] Preferably, the cable includes, from the inside out, a copper core, a first insulation layer, a braided shielding layer, and a second insulation layer in the radial direction.

[0010] Preferably, after the braided shielding layer is peeled off, it is folded in the opposite direction to the outside of the second insulating layer to form the first shielding segment and the second shielding segment, respectively.

[0011] Preferably, the outer side of the cable is provided with a corrugated tube.

[0012] Preferably, a first heat shrink tubing is wrapped around the junction of the corrugated pipe and the cable.

[0013] Preferably, a second heat shrink tubing is provided on the outer side of both the first crimping section and the second crimping section.

[0014] Preferably, the shielding ring is fitted onto the outer wall of the base and is located near the junction of the second shielding section and the second crimping section.

[0015] Preferably, the first connector is a wire lug.

[0016] Compared with existing technologies, the DC cable harness for all-in-one controllers provided by this utility model has the following substantial features and advancements: The DC cable harness for all-in-one controllers employs a segmented crimping design with a first crimping section at the beginning and a second crimping section at the end, precisely controlling crimping parameters and effectively avoiding problems such as loose connections and over-crimping. Simultaneously, layered stripping protects cable integrity, significantly improving the reliability of crimped connections and ensuring stable transmission of high voltage and high current. Through the synergistic effect of the shielding sleeve at the beginning and the base and shielding ring at the end, a comprehensive sealed protective barrier is constructed while achieving shielding functionality, blocking the intrusion of moisture and dust, preventing copper wire oxidation and corrosion, and reducing the risk of detachment. Furthermore, the reasonable arrangement of the shielding sleeve and shielding ring eliminates shielding breaks at the transition section between the terminals and the cable, forming full-section shielding from the first connector to the second connector. This not only blocks the electromagnetic radiation of the cable harness itself from interfering with surrounding systems but also resists external electromagnetic interference, ensuring transmission stability. The overall design is compatible with the connection requirements of all-in-one controllers and battery packs, improving safety and durability. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the structure of a DC wiring harness for an all-in-one controller according to an embodiment of this utility model.

[0018] Figure 2 yes Figure 1 A magnified schematic diagram of the structure at point A in the middle.

[0019] Reference numerals: 1. First connector; 2. Cable; 3. Second connector; 4. First stripping structure; 5. Second stripping structure; 6. Shielding sleeve; 7. Corrugated tube; 8. First heat shrink tubing; 9. Second heat shrink tubing; 10. Shielding ring; 21. Copper core; 22. First insulation layer; 23. Braided shielding layer; 24. Second insulation layer; 31. Base; 32. Crimping terminal. Detailed Implementation

[0020] The specific embodiments of this utility model will now be described in detail with reference to the accompanying drawings.

[0021] Currently, DC harnesses are suitable for applications where multi-in-one controllers connect to battery packs. However, in terms of connection reliability, terminals and cables often use cold-pressing processes and lack targeted segmented crimping designs, which can easily lead to problems such as incomplete connections and over-crimping. This results in insufficient mechanical connection strength and increased contact resistance at the crimped joints, affecting the stability of high-voltage and high-current transmission. In terms of shielding effectiveness, the cable shielding layer does not cover the entire length. In particular, at the transition section between the terminal and the conductor, there are instances where the shielding layer is cut off and does not extend to the terminal shell, forming shielding breaks. This makes it difficult to prevent the strong electromagnetic radiation generated when the harness transmits high current from interfering with surrounding systems, and it is also difficult to resist the intrusion of external electromagnetic interference, affecting transmission stability.

[0022] This invention proposes a DC wiring harness for an all-in-one controller, aiming to improve the connection reliability of the DC wiring harness, enhance its sealing and protection performance, and improve its full-section shielding effect.

[0023] like Figure 1 As shown, a DC wiring harness for an all-in-one controller includes a first connector 1, a cable 2, and a second connector 3 connected in sequence. The first end of the cable 2 is provided with a first stripping structure 4, and the tail end of the cable 2 is provided with a second stripping structure 5.

[0024] The first stripping structure 4 includes a first crimping section and a first shielding section arranged sequentially along the axial direction of the cable 2 from the beginning to the end, and a shielding sleeve 6 is crimped onto the outside of the first shielding section. The second stripping structure 5 includes a second crimping section and a second shielding section arranged sequentially along the axial direction of the cable 2 from the end to the beginning.

[0025] The first connector 1 is crimped into the first crimp section, and the first connector 1 is configured to connect the cable 2 to the interface of the all-in-one controller.

[0026] like Figure 1 and Figure 2 As shown, the second connector 3 includes a base 31 and a crimp terminal 32. The crimp terminal 32 is crimped into the second crimp section. The base 31 is mounted on the second shielding section. A shielding ring 10 is provided on the outer side of the base 31. The second connector 3 is configured to connect the cable 2 to the interface of the battery pack unit using the crimp terminal 32 and the base 31.

[0027] In this embodiment of the invention, which addresses the connection scenario between the all-in-one controller and the battery pack, the cable 2 is selected as a high-voltage DC dedicated type, such as... Figure 2 As shown, the cable 2 includes, from the inside to the outside, a copper core 21, a first insulation layer 22, a braided shielding layer 23, and a second insulation layer 24 in the radial direction.

[0028] For example, the copper core 21 is made of high-purity electrolytic copper, and its cross-sectional area is designed to meet the current requirements of the all-in-one controller and battery pack. The first insulation layer 22 is made of high-voltage resistant cross-linked polyethylene, with a thickness of 1.2 mm and a temperature resistance rating of -40℃ to 125℃. The braided shielding layer 23 is made of tin-plated copper wire, with a braiding density of ≥85% to ensure electromagnetic shielding effectiveness. The second insulation layer 24 is made of flame-retardant polyolefin, with a thickness of 0.8 mm, and possesses scratch-resistant and aging-resistant properties.

[0029] To further enhance the protection performance of cable 2, such as Figure 1As shown, a corrugated tube 7 is provided on the outer side of the cable 2. For example, a PA66 corrugated tube 7 is fitted on the outer side of the cable 2. The inner diameter of the corrugated tube 7 is adapted to the outer diameter of the cable 2, and the two ends of the corrugated tube 7 and the cable 2 are wrapped with a first heat shrink tube 8 made of double-walled adhesive heat shrink tubing. After shrinking, the inner diameter of the first heat shrink tube 8 fits the cable 2 and the outer wall of the corrugated tube 7 to achieve a sealed protection.

[0030] like Figure 1 As shown, the first connector 1 is a standard copper lug, and the lug model is compatible with the interface specifications of the multi-function controller, which is used to achieve a fixed connection between the cable 2 and the interface of the multi-function controller.

[0031] like Figure 1 and Figure 2 As shown, the second connector 3 includes a flame-retardant nylon base 31, a copper crimp terminal 32, and a tin-phosphor bronze shielding ring 10. The inner wall of the base 31 has a slot adapted to the second shielding section of the cable 2. The crimp terminal 32 is structurally matched to the copper core 21 of the cable 2 and can withstand a pull-out force of ≥500N after crimping. The inner diameter of the shielding ring 10 is adapted to the outer wall of the base 31, and its thickness is 2mm. These three components together achieve the connection and shielding protection between the cable 2 and the battery pack unit interface.

[0032] A second heat shrink tubing 9 is provided on the outer side of both the first and second crimping sections. After shrinking, the inner diameter of the second heat shrink tubing 9 fits the outer diameter of the crimping section and its length is 30mm.

[0033] In the embodiment of this utility model, when manufacturing a DC wiring harness for an all-in-one controller, the first step is to strip the cable 2. The first stripping structure 4 at the end of the cable 2 near the all-in-one controller needs to be processed sequentially along the axial direction of the cable 2 from the beginning to the end, including the first crimping section and the first shielding section. The first crimping section has a 30mm length of the second insulation layer 24, the braided shielding layer 23, and the first insulation layer 22 stripped, leaving only the copper core 21 exposed.

[0034] The first shielding section is located outside the first crimping section. After removing the second insulating layer 24 with a length of 20mm, the braided shielding layer 23 is folded in the opposite direction to the outside of the second insulating layer 24 to form a ring structure. The coverage length of the folded braided shielding layer 23 is adapted to the shielding sleeve 6.

[0035] The second stripping structure 5 at the end of cable 2 near the battery pack is processed along the axial direction of cable 2 from the end to the beginning, with the second crimping section and the second shielding section processed sequentially. The second crimping section also has a 30mm long second insulation layer 24, braided shielding layer 23 and first insulation layer 22 stripped to expose the copper core 21. The second shielding section is located outside the second crimping section. After stripping the 25mm long second insulation layer 24, the braided shielding layer 23 is folded in the opposite direction to the outside of the second insulation layer 24 to form a ring structure. After folding, the outer diameter of the braided shielding layer 23 is adapted to the slot of the base 31 of the second connector 3.

[0036] After stripping the wires, the shielding components are assembled. The shielding sleeve 6 is placed on the outside of the first shielding section, and the shielding sleeve 6 is pressed with a hydraulic crimping tool to ensure that the shielding sleeve 6 fits tightly with the reverse-folded braided shielding layer 23 without gaps, thus preventing the shielding layer from being cut off at the first end joint.

[0037] Furthermore, the base 31 of the second connector 3 is fitted onto the outside of the second shielding section, so that the groove on the inner wall of the base 31 engages and fixes with the reverse-folded braided shielding layer 23. Then, the shielding ring 10 is fitted onto the outer wall of the base 31. The shielding ring 10 needs to be located near the junction of the second shielding section and the second crimping section. The shielding ring 10 and the base 31 are fixed by interference fit, so that the braided shielding layer 23 of the second shielding section forms an effective connection with the shielding ring 10 through the base 31, thereby covering the transition section between the terminal and the cable 2.

[0038] When crimping the first connector 1, the wire lug, which serves as the first connector 1, is fitted onto the exposed copper core 21 of the first crimping section. A special crimping mold is used to crimp it, and the crimping force is set to 80kN to ensure that the contact resistance at the crimping point is ≤5mΩ. After the crimping is completed, the second heat shrink tubing 9 is fitted onto the outside of the first crimping section. The heat shrink tubing is shrunk by heating with a hot air gun to tightly wrap the connection between the first crimping section and the first connector 1, thereby achieving sealing and insulation protection.

[0039] When crimping the second connector 3, the crimping terminal 32 of the second connector 3 is sleeved on the exposed copper core 21 of the second crimping section. The same crimping mold as the first connector 1 is used to crimp with a crimping force of 80kN. After crimping, the second heat shrink tube 9 is also sleeved on the outside of the second crimping section and heated to shrink, so as to achieve sealing protection at the connection between the second crimping section and the crimping terminal 32.

[0040] The DC cable harness for an all-in-one controller proposed in this embodiment of the invention uses a segmented crimping design with a first crimping section at the beginning and a second crimping section at the end. This design precisely controls the crimping parameters, effectively avoids problems such as loose connections and over-crimping, and at the same time protects the integrity of the cable 2 by layered stripping, greatly improving the reliability of the crimping connection and ensuring stable transmission of high voltage and high current.

[0041] The DC harness used in the all-in-one controller also utilizes the synergistic effect of the shielding sleeve 6 at the beginning and the base 31 and shielding ring 10 at the end to build an all-round sealed protective barrier while achieving the shielding function. This can block the intrusion of moisture and dust, prevent the copper wire from oxidizing and rusting, and thus reduce the risk of detachment.

[0042] In addition, the DC harness used in the all-in-one controller eliminates the shielding breakpoint at the transition section between the terminal and the cable 2 through the reasonable layout of the shielding sleeve 6 and the shielding ring 10, forming full-length shielding from the first connector 1 to the second connector 3. This not only blocks the electromagnetic radiation generated by the harness itself from interfering with the surrounding system, but also resists external electromagnetic interference, ensuring transmission stability and accurately adapting to the connection requirements of the all-in-one controller and the battery pack, effectively improving safety and durability during use.

[0043] This utility model is not limited to the specific technical solutions described in the above embodiments. Besides the above embodiments, this utility model may have other implementation methods. For those skilled in the art, any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. A DC wiring harness for an all-in-one controller, comprising a first connector (1), a cable (2), and a second connector (3) connected in sequence, characterized in that, The first end of the cable (2) is provided with a first stripping structure (4), and the tail end of the cable (2) is provided with a second stripping structure (5). The first stripping structure (4) includes a first crimping section and a first shielding section arranged sequentially from the first end to the tail end along the axial direction of the cable (2). A shielding sleeve (6) is crimped onto the outside of the first shielding section. The second stripping structure (5) includes a second crimping section and a second shielding section arranged sequentially from the tail end to the head end along the axial direction of the cable (2); The first connector (1) is crimped into the first crimp section, and the first connector (1) is configured to connect the cable (2) to the interface of the all-in-one controller; The second connector (3) includes a base (31) and a crimp terminal (32), the crimp terminal (32) being crimped into a second crimp section, the base (31) being mounted on a second shield section, and a shielding ring (10) being provided on the outside of the base (31). The second connector (3) is configured to connect the cable (2) to the interface of the battery pack unit using the crimp terminal (32) and the base (31).

2. The DC wiring harness for an all-in-one controller according to claim 1, characterized in that, The cable (2) includes, in the radial direction from the inside out, a copper core (21), a first insulation layer (22), a braided shielding layer (23), and a second insulation layer (24).

3. The DC wiring harness for an all-in-one controller according to claim 2, characterized in that, After the braided shielding layer (23) is peeled off, it is folded in the opposite direction on the outside of the second insulating layer (24) to form the first shielding segment and the second shielding segment respectively.

4. The DC wiring harness for an all-in-one controller according to claim 1, characterized in that, The cable (2) is provided with a corrugated pipe (7) on its outer side.

5. The DC wiring harness for an all-in-one controller according to claim 4, characterized in that, The first heat shrink tubing (8) is wrapped around the junction of the corrugated pipe (7) and the cable (2).

6. The DC wiring harness for an all-in-one controller according to claim 1, characterized in that, A second heat shrink tubing (9) is provided on the outer side of both the first crimping section and the second crimping section.

7. The DC wiring harness for an all-in-one controller according to claim 1, characterized in that, The shielding ring (10) is fitted on the outer wall of the base (31) and is located near the junction of the second shielding section and the second crimping section.

8. The DC wiring harness for an all-in-one controller according to claim 1, characterized in that, The first connector (1) is a wire lug.

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