Abstract
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.
Highlights
HEVs and EVs rapidly became widely used since the 2000’s
The electromagnetic shield was initially achieved with individual shielded wire, and we introduced the braided wire bundle shield wiring harness into the Toyota PRIUS in 2003, and in 2005 the first pipe shield technology for the Honda CIVIC HYBRID
The mechanical protection of a conventional wiring harness is usually done with large plastic protectors and additional plastic convoluted tubes, which are produced via injection and extrusion moulding processes
Summary
HEVs and EVs rapidly became widely used since the 2000’s. Many units which are mounted onto these HEVs and EVs, e.g. the motor, the inverter and the high-voltage battery, have been developed and improved due to their popularity. The connecting high-voltage wiring harness between units has been progressed. This advance produces challenges to cost reduction, weight reduction and space saving. We have one innovative solution for these challenges
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