Shenzhen Guchen Electronic recently completed the successful delivery of 272 sets of 500A high voltage connectors, including straight plugs and metal receptacles without HVIL. These GCMC1 series components are designed for 95mm² unshielded cables and tailored for demanding EV power systems.

Shenzhen Guchen Electronic has completed the production and shipment of 36 custom 60A high voltage cable assemblies for use in EV power distribution systems. Each cable features a PRC082-60-10 connector and M6 terminal, designed for secure connections to PDUs and other HV components.

High-voltage wiring harnesses play a crucial role in powering and protecting key systems within electric vehicles. However, faults in these systems can result in safety hazards, vehicle malfunction, or even catastrophic damage. This article outlines four critical methods to prevent HV wiring harness failures: designing application-specific harnesses, ensuring component compatibility, selecting high-quality materials for demanding environments, and eliminating crimping or soldering issues. By addressing these areas, OEMs and harness manufacturers can ensure safe, reliable, and long-lasting EV performance.

The wire harness industry, integral to sectors like automotive, communications, and industrial manufacturing, is embracing rapid technological advancements. Innovations in AI and automation are improving design precision and manufacturing efficiency.

Unlike conventional cables, EV high-voltage cables must withstand extreme temperatures (up to 175°C in some cases) and transmit high currents (up to 450A). Common insulation materials such as XLPE, silicone rubber (SIR), and thermoplastic elastomers (TPE) are selected based on their temperature resistance, flexibility, and mechanical properties.

HV wiring harnesses are critical components in EVs, ensuring safe and reliable power distribution. These harnesses undergo rigorous testing to meet stringent industry standards and guarantee performance in various conditions. Key tests include electrical performance checks such as dielectric withstand, continuity, and insulation resistance; mechanical durability assessments like tensile strength and vibration resistance; and environmental tests, including temperature cycling and humidity resistance. Additionally, tests for EMI and HVIL safety features are essential for ensuring safety. This comprehensive testing process is crucial for the durability, safety, and compliance of EVs, particularly in the challenging automotive and energy environments.