In order to reduce the environmental impact of motor vehicles and meet the requirements of fuel economy and carbon dioxide emission regulations. The promotion of hybrid and electric vehicles is a good choice for automobile manufacturers. In the coming years, the global demand for these alternative energy vehicles will continue to increase.
However, while electric vehicles bring about environmental protection, they also have their own imperfections. How to shield the electromagnetic waves generated during the high-voltage operation of electric vehicles, as well as the interference of the vehicle's wiring, the sealing performance of the wiring and connectors. Therefore, when designing and developing hybrid and electric vehicles, these problems need to be solved; otherwise, safety hazards will arise.
Electromagnetic wave shielding, a solution to the interference problem of wiring harnesses. Hybrid vehicles have attracted much attention due to their fuel economy, but at the same time, they have also presented challenges for automobile manufacturers, namely electromagnetic interference (EMI). Optimizing electromagnetic interference through the design of electronic modules and wiring harnesses is always necessary, even in a 12V system. This harmful noise can interfere with radio reception and other vehicle signals such as AM/FM radio frequencies, mobile phone usage, and Bluetooth performance. Hybrid vehicles rely on high-current and high-voltage inverters to operate. However, high-power inverters generate electromagnetic interference within the frequency range of 100.0 kHz to 200.0 MHz. The high-power AC and DC conversion of these inverters makes the electromagnetic interference problem of hybrid vehicles even more severe.
In contrast, when converting alternating current to direct current and charging the battery pack, the weight of the electronic devices is lighter, and thus they have better performance compared to transformers. In fact, electronic devices are currently the only feasible technology applicable for converting AC and DC and powering vehicles with battery packs. However, these electronic devices generate more electromagnetic interference because the high-voltage wiring acts as an electromagnetic interference antenna, transmitting electromagnetic interference throughout the vehicle body.
In traditional vehicles, the most effective way to suppress electromagnetic interference noise is often to use components such as capacitors, sensors, and diodes. However, nowadays, shielding electronic modules and wiring harnesses has become a more economical solution for hybrid vehicles, as it is smaller and lighter compared to traditional suppression components.
The solution to the safety issues of wiring connectors.
To ensure the safety of drivers and maintenance technicians in a high-voltage environment, we must consider a series of complex factors of the electrical system to ensure reliability and optimality. The connection system is a key component of high-voltage electrical wiring harnesses, especially for the design of high-power circuits. From a safety perspective, in the design of high-voltage connection systems, two aspects need to be noted: the high-voltage interlock circuit (HVIL) and the environmental sealing of the connectors (to prevent short circuits between high-voltage terminals when the vehicle is in use).