Various high-voltage components such as electric vehicle power battery to high-voltage distributor, motor controller to motor, AC and DC charging are connected through high-voltage wiring harnesses. The internal wiring of electric vehicles is complex, and the high-voltage wiring harness layout inevitably needs to pass through the sharp edge or through the hole. At this time, in order to protect the safety of the wiring harness, it is necessary to protect the high-voltage wiring harness design, and the high-voltage wiring harness should avoid the development of heat sources and vibration positions when the vehicle is developed. The high-voltage wire harness carries a larger current and voltage, and the wire diameter and weight are larger. In order to avoid stress concentration in the same place, the minimum bending radius of the high-voltage cable is generally greater than 5 times the wire diameter.

The wiring of the high voltage wiring harness of the drive motor should consider the influence of the motion and vibration of the components, and the size of the high voltage wiring harness should be reasonably designed to meet the stress of the length distribution, but also to avoid the wiring harness too long and lead to accumulation. In order to avoid damage to the harness and other parts, the harness should increase the fixed structure design of the rubber cushion and guide groove.

There is EMC electromagnetic interference inside the car. In order to reduce and avoid the impact of electromagnetic interference on high-voltage components, the high-voltage wiring harness adopts a shielding structure to avoid high-frequency noise emission. It is worth noting that in order to avoid interference caused by overlapping of high-voltage wiring harnesses, high-low-voltage wiring harnesses must be separated from each other.

High voltage has long exceeded the safety voltage of the human body, the car body adopts the same way of taking iron as the low voltage system, in order to use safe and reliable, the high voltage wiring harness must use the double track system.

High-voltage connector is an important part of high-voltage wiring harness, in the selection of the need to focus on the rated operating voltage, current, insulation resistance, voltage rating, shielding and interlock and other related electrical performance parameters. Electric vehicles often use built-in high-voltage interlocks because of their more compact layout and smaller size. High voltage connectors usually need to test vibration resistance and the corresponding mechanical life, which is also one of the ways to test whether the mechanical properties are good.