The conventional high-voltage wiring harness for HEV is composed of wires and plastic protectors. Because of low heat transfer of the plastic protector, the larger sized wire is needed for high-voltage wiring harness to reduce the Joule-heat loss. Furthermore, high design cost and long lead-time are required to make the mould for a new or modified protector. We have developed the pipe shield wiring harness to eliminate these problems. The pipe shield wiring harness is already in mass-production for Honda CIVIC HYBRID, INSIGHT, CR-Z and FIT HYBRID etc. In this paper, we explain the characteristics and the structure of the conventional high-voltage wiring harness against those of the innovative pipe shield wiring harness. Heat resistance against an external source, weight reduction, simplification of wiring harness assembly and sheath design, electromagnetic shielding performance, and resistance to stone chipping, are described. The final beneficial feature of the pipe shield wiring harness is its resistance to stone chipping which is required due to its under-floor routing of the high-voltage wiring harness. A painted aluminium alloy pipe sample was tested for its resistance against stones and a later additional exposure to a corrosive salt environment. Fig. 18 shows the results of these tests. After the first stone chipping test, scratches on the painted surface were observed and limited paint peeling occurred. However after the additional salt spray test according to one of our customer's specifications, no further spread of paint scratches and peeling occurred. So the pipe shield w/h concept also provides a very good abrasion protection.
Pipe shield high-voltage wiring harness
EVS, Electric Vehicle Symposium, 26 ; 2468-2474
2012
7 Seiten, 18 Bilder
Conference paper
English