New energy all-in-one controller DC output integrated wire harness

Abstract

The utility model provides a new energy all -in -one controller DC output integrated wiring harness, including electric wire and connector, still including rubber bush, sheet metal card and ribbon, the electric wire both ends are respectively pressure -welded with terminal, and are inserted into the connector through terminal, form electric connection, the rubber bush is sleeved in electric wire, is located sheet metal card installation position, is used for preventing wiring harness abrasion, the strip tight mouth that passes through is set up on the rubber bush along the axial direction, is set up annular recess on the outer wall of rubber bush, sheet metal card is located in the annular recess of rubber bush, the ribbon passes through sheet metal card and is tied on the outside of rubber bush, tight fastening sheet metal card and rubber bush as a whole. This high -voltage wiring harness fixing scheme has outstanding advantages in reliability, safety and assembly convenience, has very high industrial application value.

Description

Technical Field

[0001] This utility model relates to the field of automotive wiring harness technology, and in particular to a DC output integrated wiring harness for a new energy all-in-one controller. Background Technology

[0002] The all-in-one controller for new energy vehicles is a core component for realizing the energy control and drive of the entire vehicle. It is electrically connected to key components such as the battery system and drive motor through a high-voltage direct current (DC) output harness. The reliability and durability of this high-voltage harness are directly related to the safety and operational stability of the entire vehicle.

[0003] Currently, the following methods are commonly used to fix these types of high-voltage wiring harnesses: one is to use ordinary nylon cable ties to directly bind the harness to the fixing point on the vehicle body; the other is to use independent plastic or metal clamps to clamp the harness and then fix the clamps to the vehicle body with bolts. However, these existing fixing methods still have the following drawbacks: Poor shock absorption and buffering capacity; the wiring harness is in direct contact with rigid fixing points (such as sheet metal holes, clamps) or only through a thin layer of insulation. The continuous vibration during vehicle operation will be directly transmitted to the wiring harness, which can easily lead to wear of the wiring harness insulation layer and even cause the risk of high voltage short circuit.

[0004] The fixing points are prone to loosening, especially in vibrating environments. Traditional cable ties or clamps are easy to loosen, causing the wiring harness to collide or rub against the vehicle body, generating noise and accelerating the damage to the wiring harness.

[0005] Therefore, there is an urgent need in this field for a more reliable wiring harness fixing solution to fundamentally improve the connection safety and service life of high-voltage wiring harnesses in new energy vehicles. Utility Model Content

[0006] In view of the above, this utility model provides a DC output integrated wiring harness for a new energy all-in-one controller, and a high-voltage wiring harness fixing solution with outstanding advantages in reliability, safety and ease of assembly, which has high industrial application value.

[0007] The present invention specifically adopts the following technical solution: a DC output integrated wiring harness for a new energy multi-function controller, including a wire and a connector, and further including a rubber sleeve, a sheet metal clip and a cable tie. Terminals are crimped to both ends of the wire and inserted into the connector through the terminals to form an electrical connection. The rubber sleeve is fitted onto the wire and located at the installation position of the sheet metal clip to prevent wear of the wiring harness. A through strip-shaped tightening opening is provided on the rubber sleeve along the axial direction. An annular groove is provided on the outer wall of the rubber sleeve. The sheet metal clip is located in the annular groove of the rubber sleeve. The cable tie passes through the sheet metal clip and is tied to the outside of the rubber sleeve, fastening the sheet metal clip and the rubber sleeve together.

[0008] As a further improved technical solution, the sheet metal clip includes an installation section and a locking section. The locking section is an arc-shaped hook structure located at the bottom of the installation section. A through hole is provided at a corresponding position on the locking section. The locking section is semi-encircled and locked in the annular groove of the rubber sleeve. The cable tie passes through the through hole and is tied to the outside of the rubber sleeve.

[0009] As a further improved technical solution, mounting holes are provided on the mounting section of the sheet metal card for connection with the body sheet metal via fasteners.

[0010] As a further improved technical solution, the connector includes a straight plug and a wire-spinning socket, which are respectively disposed at both ends of the wire for connecting to the vehicle wiring harness and the electric drive electrical module.

[0011] As a further improved technical solution, a buckle is provided on the side wall of the cable receptacle. The buckle has an elastic, protruding cedar-shaped structure, and the cable receptacle is connected to the vehicle wiring harness connector through the buckle.

[0012] As a further improved technical solution, at least one threaded head cable tie or cedar head cable tie is also looped around the wire.

[0013] As a further improved technical solution, an anti-detachment washer is provided inside the mounting hole.

[0014] As a further improved technical solution, a label is also ringed around the wire, which is used to mark the specifications, uses and connection correspondence information of the wire harness.

[0015] This utility model's new energy all-in-one controller DC output integrated wiring harness achieves a single action and double fastening effect through the unique collaborative design of the protective components: "rubber sleeve strip tightening opening + sheet metal clip through hole + cable tie". When the cable tie is tightened, its radial contraction force is simultaneously converted into a radial clamping force on the wire and a locking force on the sheet metal clip, forming a rigid "integrated fixing assembly". This structure has extremely strong vibration and impact resistance, fundamentally avoiding the risk of loosening of the fixing point and improving the reliability of the fixation.

[0016] In addition, the elastic rubber sleeve of this application serves as a buffer, with the sheet metal clip located within the groove of the rubber sleeve, effectively isolating the wiring harness from direct contact with the rigid sheet metal clip and the vehicle body. The vibration energy of the vehicle is effectively absorbed and attenuated by the rubber sleeve, completely avoiding the problem of wear on the wiring harness insulation layer caused by vibration, and greatly improving safety. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the overall structure of the DC output integrated wiring harness of the new energy all-in-one controller in this application.

[0018] Figure 2 This is a schematic diagram of the integrated wire harness in this application.

[0019] Figure 3 This is a schematic diagram of the sheet metal card structure for this application. Detailed Implementation

[0020] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, the accompanying drawings show only the parts relevant to the present invention, not the entire structure.

[0021] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "set up" and "connection" 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; they can refer to the internal connection of two components. For those skilled in the art, the specific meaning of the above terms in this utility model can be understood through the specific circumstances. Example 1

[0022] Reference Figure 1 and Figure 2 This embodiment describes a DC output integrated wiring harness for a new energy all-in-one controller, including a wire 1 and a connector, as well as a rubber sleeve 2, sheet metal clips 3, and cable ties 4. The wire 1 uses readily available high-voltage cables conforming to automotive industry standards, with a rated operating voltage of 1000V~1500VDC. After stripping the wires at both ends, the terminals are crimped securely and inserted into the connector to form an electrical connection. The connector includes a straight plug 5 and a wire-spinning socket 6, respectively located at both ends of the wire 1, for connecting to the vehicle wiring harness and the electric drive electrical module. The specific models of the straight plug 5 and wire-spinning socket 6 can be selected according to actual needs. For example, in a new energy vehicle wiring harness, the Tianhai PP3203161 straight plug and the Tianhai PP3214301 wire-spinning socket can be selected. The side wall of the cable receptacle 6 is provided with a buckle 7. The buckle 7 has an elastic, protruding cedar-shaped structure. The cable receptacle 6 connects to the vehicle wiring harness connector through the buckle 7. When it connects to the plug-in connector of the vehicle power supply wiring harness, the buckle 7 can automatically lock to ensure reliable connection and prevent the connection from coming loose due to vibration during vehicle operation.

[0023] Specifically, the rubber sleeve 2 is fitted onto the wire 1 and located at the installation position of the sheet metal clip 3. In this embodiment, the rubber sleeve 2 is fitted onto one end near the straight plug 5 to prevent wire harness wear. The rubber sleeve 2 has a through strip-shaped tightening opening 21 along the axial direction. An annular groove 22 is provided on the outer wall of the rubber sleeve 2. The sheet metal clip 3 is located in the annular groove 22 of the rubber sleeve 2. The cable tie 4 passes through the sheet metal clip 3 and is tied to the outside of the rubber sleeve 2 to fasten the sheet metal clip 3 and the rubber sleeve 2 together.

[0024] Further integration Figure 3 The sheet metal clip 3 includes an integrally formed mounting section 31 and a locking section 32. The locking section 32 is an arc-shaped hook structure located at the bottom of the mounting section 31. A through hole 33 is provided at a corresponding position on the locking section 32. The locking section 32 is semi-encircled and locked in the annular groove 22 of the rubber sleeve 2. The cable tie 4 passes through the through hole 33 and is tied to the outside of the rubber sleeve 2. As the cable tie 4 tightens, a strong radial contraction force is generated and acts on the outer wall of the rubber sleeve 2. This contraction force forces the rubber sleeve 2 to undergo elastic deformation, and the width of the strip tightening opening 21 on it becomes significantly narrower. The narrowing of the strip tightening opening 21 causes the inner diameter of the rubber sleeve 2 to decrease, thereby uniformly and tightly holding the internal wire 1 from all sides. At the same time, the tightened cable tie 4, through its direct action with the through hole 33, firmly locks the sheet metal clip 3 onto the rubber sleeve 2.

[0025] Mounting holes 34 are provided on the mounting section 31 of the sheet metal clip 3 for connecting to the body sheet metal via fasteners. Anti-detachment washers are provided inside the mounting holes 34, and the fasteners can be bolts, connecting the sheet metal clip 3 to the external fixing structure to achieve overall positional fixation of the wiring harness.

[0026] At least one threaded cable tie 4b or cedar cable tie, commonly used in automotive wiring harnesses, is looped around the wire 1 and tied to the bend or branch point of the wiring harness for wiring harness routing management and auxiliary fixation.

[0027] A label 8 is also ringed around the wire 1. The label 8 is used to mark the specifications, uses and connection information of the wire harness.

[0028] During assembly, operators only need to complete four simple steps—"fitting, clamping, securing, and tightening"—at preset positions. This greatly simplifies the operation, reduces reliance on worker skills, and ensures a high degree of consistency in product quality for each vehicle. It is particularly suitable for the high-speed requirements of automated production lines. Example 2

[0029] A protective assembly for the DC output integrated wiring harness of a new energy all-in-one controller includes a rubber sleeve 2, a sheet metal clip 3, and cable ties 4 as described in Embodiment 1. The method of use is as follows: The user places the rubber sleeve 2 onto the existing automotive high-voltage wiring harness that needs to be secured and protected. The sheet metal clip 3 is then fitted into the designated position on the rubber sleeve 2. The cable ties 4 are used to tightly secure the assembly, forming a fixed assembly. Finally, the entire assembly is secured to the vehicle body using bolts through the mounting holes 31 on the sheet metal clip 3.

[0030] Furthermore, the above embodiments are only used to illustrate the present utility model and are not intended to limit the technical solutions described in the present utility model. The understanding of this specification should be based on those skilled in the art. Although the present utility model has been described in detail with reference to the above embodiments, those skilled in the art should understand that they can still make modifications or equivalent substitutions to the present utility model. All technical solutions and improvements that do not depart from the spirit and scope of the present utility model should be covered within the scope of the claims of the present utility model.

Claims

1. A new energy all-in-one controller DC output integrated wiring harness, comprising wires and connectors, characterized in that: It also includes a rubber sleeve, a sheet metal clip, and cable ties. Terminals are crimped to both ends of the wire, and these terminals are inserted into a connector to form an electrical connection. The rubber sleeve is fitted onto the wire at the installation position of the sheet metal clip to prevent wire harness wear. The rubber sleeve has a through-hole strip-shaped tightening opening along its axial direction, and an annular groove is formed on the outer wall of the rubber sleeve. The sheet metal clip is placed within the annular groove of the rubber sleeve. The cable ties pass through the sheet metal clip and are tied to the outside of the rubber sleeve, securing the sheet metal clip and the rubber sleeve together. The sheet metal clip includes an installation section and a locking section. The locking section has an arc-shaped hook structure located at the bottom of the installation section, and a through hole is formed at a corresponding position on the locking section. The locking section semi-circularly encircles the wire. The cable tie, located within the annular groove of the rubber sleeve, passes through the perforation and is secured to the outside of the rubber sleeve. An mounting hole is provided on the mounting section of the sheet metal clip for connection to the vehicle body sheet metal via fasteners. The connector includes a straight plug and a wire-spinning socket, respectively located at both ends of the wire, for connection to the vehicle wiring harness and electric drive electrical module. A buckle is provided on the side wall of the wire-spinning socket; the buckle has an elastic, protruding, cedar-shaped structure, and the wire-spinning socket mates with the vehicle wiring harness connector via the buckle. At least one threaded cable tie or cedar-shaped cable tie is also looped around the wire. An anti-detachment washer is provided within the mounting hole. A label is also looped around the wire, indicating the specifications, purpose, and connection information of the wiring harness.

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