How do new energy wiring harnesses ensure safe isolation during high-voltage power transmission through high-insulation materials and shielding structures?
Publish Time: 2025-10-15
In the electrical systems of new energy vehicles, high-voltage power flows like blood through blood vessels, flowing through the three core components of the battery, electronic control, and motor, supporting the vehicle's power output. However, while high voltage brings powerful performance, it also carries significant safety risks. Insulation failure, arcing, or electromagnetic interference can not only cause system failure but also endanger the safety of drivers and passengers. In this context, new energy wiring harnesses are no longer just conductive pathways; they are also a critical barrier to ensure high-voltage safety. Their core function is to achieve reliable electrical isolation and electromagnetic protection while transmitting high-speed power through the coordinated design of high-insulation materials and sophisticated shielding structures, creating an invisible yet crucial safety line.
New energy wiring harnesses carry voltages far exceeding those of traditional low-voltage systems, and their operating environments are more demanding: frequent vibration, drastic temperature fluctuations, and corrosion from moisture and oil all place extremely high demands on material stability. To address these challenges, wiring harnesses utilize a multi-layer composite structure. The innermost conductor is responsible for power transmission, while the outer layer of high-insulation material provides primary isolation. These materials are typically high-performance polymers such as cross-linked polyethylene, silicone rubber, or radiation-cross-linked polyolefin. These materials possess exceptionally high dielectric strength, effectively preventing current leakage at high voltages. Even under high temperatures or after prolonged use, their insulation performance remains stable, preventing breakdown or leakage due to aging. This "core protection" ensures that high-voltage electricity always flows along its intended path, preventing accidental contact with the vehicle's metal structure or other wiring.
However, insulation alone is not sufficient to address all risks. High-voltage current transmission generates strong electromagnetic fields. If uncontrolled, these fields can interfere with onboard communications, sensor signals, and even safety control systems, causing misjudgments or malfunctions. To address this, new energy wiring harnesses incorporate a sophisticated shielding structure outside the insulation layer, typically employing a copper braid, aluminum foil wrap, or a double-layer shielding combination. This shielding layer acts as an electromagnetic "shield," effectively absorbing or reflecting electromagnetic radiation generated by the conductors, preventing it from dissipating. At the same time, the shielding layer, through reliable grounding, diverts induced currents to the earth, preventing them from becoming a source of interference. This "active suppression" mechanism ensures peaceful coexistence between high-voltage and low-voltage electronic systems, safeguarding the stable operation of the vehicle's electronic control system.
In addition, the shielding structure provides physical protection. During vehicle operation, the wiring harness may come into contact with metal components due to vibration or friction. Without the protection of a shielding layer, this can easily cause insulation wear, leading to short circuits. The copper wire braid or aluminum foil layer not only enhances the overall strength of the wiring harness but also prioritizes damage from minor scratches, protecting the internal insulation layer from damage. Some high-end wiring harnesses also include a wear-resistant sheath over the shielding layer to further enhance resistance to mechanical damage.
Safe isolation is also crucial at the connection port. The wiring harness's terminal crimping, sealing process, and connector design are rigorously verified to ensure that the high-voltage interface remains airtight and electrically tight despite insertion and removal, vibration, and temperature fluctuations. Designs such as waterproof rubber rings, secondary locking mechanisms, and a high-voltage interlock circuit (HVIL) further enhance connection reliability, preventing arcing or short circuits caused by looseness or water ingress. Ultimately, the value of the new energy wiring harness lies not in how much energy it transmits, but in how it ensures the safe and controlled flow of that energy. It uses highly insulating materials to create a physical barrier and shielding structures to weave an electromagnetic defense line, confining dangerous high voltage electricity to a safe path. Behind this silent "energy channel" lies the deep integration of materials science, electrical engineering, and manufacturing processes. Unnoticed, it silently safeguards the safety of drivers and passengers with every acceleration and every charge. It is this invisible protection that makes electric mobility not only efficient but also trustworthy.
