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102025-09Electrical Contact Reliability of EV Connectors and the Application of Copper MaterialsCopper is essential for automotive connectors, affecting conductivity, strength, and reliability. This study reviews contact design, failure mechanisms, material selection, and manufacturing/testing processes. Optimized copper alloys enhance electrical performance, thermal stability, and wear resistance, ensuring long-term reliability for conventional, new energy, and high-frequency automotive and electronic applications.Learn More >>
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252025-07Revealing the MSD Service Disconnect: A Key to Electrical Safety!The Manual Service Disconnect (MSD) serves as a critical safety device in electric vehicle and new energy high-voltage systems, providing protection against short circuits and overloads during maintenance. MSDs incorporate high-voltage fuses and interlock functions to ensure operational safety. Key performance criteria include UL94 V-0 flame resistance, IP67/IP6K9K ingress protection, tool-free manual disconnection, and a locking mechanism to prevent misoperation.Learn More >>
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162025-07Optimization of Shielding Structure in EV High-Voltage CablesAs electric vehicles continue to gain traction worldwide, ensuring the reliability of high-voltage components becomes a central focus of vehicle design. Among these, high-voltage cables serve as the critical arteries for energy transmission. This article presents a comparative analysis of various shielding structures used in high-voltage cables and highlights a new design—an extruded semi-conductive layer combined with tinned copper braid shielding. The new structure significantly improves cable lifespan and shielding performance without compromising flexibility or increasing production costs.Learn More >>
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212025-044 Ways to Prevent Automotive High-Voltage Wiring Harness FailuresHigh-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.Learn More >>
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032025-03Wire Harness Industry: Technological Innovation Drives the Future of Intelligence, Lightweighting, and SustainabilityThe 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.Learn More >>
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242025-02Requirements for the Insulation Layer of EV High Voltage CablesUnlike 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.Learn More >>