Design of wire slot support for high voltage wire harness

Blog | news | Jan 14,2023

To correctly design the wire slots for high-voltage wire harnesses, it is necessary to clarify the boundary data, surrounding environment requirements, and design requirements for wire slots for high-voltage wire harnesses, which is also the basic input for type selection requirements.

Design input of high-voltage wire harness trunking

Layout data of high voltage system

The trunking design is not designed out of thin air. When designing the trunking, it is necessary to input boundary data, that is, the vehicle position data of the components related to the trunking design.

Vehicle Environment Requirements Input

The design and selection of any component need to consider the environment and use conditions. Due to the complex environment of the vehicle, the temperature requirements and vibration requirements of different parts are not the same. When we design the high-voltage wire harness bracket, we should ensure that it can normally work.

Usage and requirements of wire harness slots

The use of wire slots has a great impact on the cost of wire harnesses. Here we mainly clarify the use of wire slots.
When the wire harness is inevitably exposed to the outside of the vehicle during the wiring harness layout process, it is more common to route the wires under the chassis.

Stone impact resistance requirements for wire slots: In many cases, wire slots are used under the chassis of vehicles to protect wire harnesses from being damaged by stones, so it is necessary to specify stone impact resistance tests for wire slots.

The wire slot can also play the role of guiding the wire harness, especially for the wiring of high-voltage wires with a large wire diameter and a small bending space. The method design needs to be determined according to the actual situation of the vehicle. the

Design points of wiring harness slotting

wiring harness slotting

General requirements for the design of high-voltage wire harness trunking:

Avoid sharp edges on the edges of the wires entering and exiting the wire slot, so as not to cut the wire harness;
The wiring harness needs to be fixed in the wire slot as needed, if the wire slot is multi-slot single-core wiring, it does not need to be fixed;
If the trunking is open, make a weep hole at the lowest point.
If there is no special requirement, corrugated tubes should not be used for the wiring harness in the trunking to reduce the design size of the trunking.
The trunking should be fixed on the same object as much as possible.
If it is unavoidable to fix two different parts, they should be fixed on parts that are fastened by welding and bolts to prevent damage to the trunking caused by strong vibration during driving;
If the trunking is used in the vehicle chassis, the metal bracket should be used first.
If plastic materials are used, standards for impact resistance, stone chip requirements, and test methods shall be specified.

Material selection

For the selection of high-voltage trunking materials, non-metallic materials such as PP, PA66, and other plastics are commonly used at present, and iron and plating are commonly used for metal materials.

It is obvious that the strength of the metal trunking is much better than that of the plastic one, but the weight is also much heavier, so the two should be selected under appropriate circumstances.

Selection of open and closed forms of trunking

When the wire harness is routed along the body sheet metal, it is necessary to use a closed wire slot. Sometimes the wire harness is routed overhead and fixed and guided through the wire slot. At this time, for the simplicity of the wire slot design and cost considerations, an open wire slot can be designed.

Selection of fixed structure for trunking

Commonly used fixing structures include bracket opening bolts and nuts fastening, body opening brackets with buckle fixing, and body welding stud brackets with buckle fixing. The fixed points are divided into positioning fixed points and general fixed points. A section of trunking must have a fixed point for positioning.

One of the above three types can be selected for the positioning and fixing point structure. Generally, it is not recommended to use the buckle fixing method for the fixing point, but to adopt the hole type, and the hole type can be a large round hole or a waist hole. The hole-type fixing structure can embed a metal ring in the hole to strengthen the strength of the fixing point.

Other requirements

The design of the trunking should consider the special requirements of the trunking, impact resistance requirements, vibration requirements, sealing, and other requirements. According to these requirements, the structural design of the incoming trunking should be reasonably carried out.

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