As a carrier for connecting electrical parts, the length, direction and position of the wire harness in the car are different, so when fixing it, we should consider its surrounding environment and choose different fixing parts and fixing methods. At the same time, the wire diameter of the high-voltage cable is thicker, and the tension required for fixing is larger, so bolts are usually used for fixing, and the main parts used are clamps and brackets.

High-voltage connection method: The connection method of high-voltage gas parts depends on the electrical parts end, usually using high-voltage connector connection and bolt connection.

Shielding treatment: Shielding treatment is crucial for the whole vehicle high-voltage electrical system, so the high-voltage wiring harness needs to be considered at the beginning of the design in accordance with the shielding requirements of the whole vehicle for the high-voltage electrical system. As far as possible, use cables and connectors with shielding layer, and in the processing of the harness, ensure the effective contact between the cable and connector shielding layer to ensure the integrity and effectiveness of shielding.

Harness testing: high-voltage harness products according to the different components to determine the specific testing standards and experimental methods. Mainly divided into electrical testing and non-electrical testing.

Electrical testing includes, voltage resistance, current resistance, voltage drop, insulation resistance, etc.; non-electrical testing includes high and low temperature, aging, hot and cold shock, salt spray, vibration, waterproof, flame retardant, airtight, terminal pulling force, etc..

Specific test items to be determined according to the choice of wiring harness connection, the requirements of the vehicle, to ensure that the selected experiments are reasonable, to avoid unnecessary waste. Experimental methods and standards can refer to national standards.
High-voltage wiring harness layout principles: high-voltage wiring harness in the layout, to fully consider the surrounding environmental factors, to avoid high-temperature heat sources, vibration, impact, etc. on the high-voltage wiring harness brought about by the damage, while taking into account the impact of electromagnetic interference on the electrical parts when the high-voltage wiring harness high current passing through.

Away from heat sources: hybrid vehicles in the presence of traditional internal combustion engine car-related parts, high-voltage wiring harnesses in the arrangement should be as far away from heat sources to avoid the occurrence of heat damage effect.

Separate high and low voltage wiring harnesses and signal lines: As cars become more and more intelligent and have more and more electrical components, signal lines and low voltage wiring harnesses become more and more complex. High-voltage harnesses in the arrangement should be as far as possible from the low-voltage harnesses and signal lines, to avoid electromagnetic interference generated by the passage of high-voltage high current to the low-voltage harnesses and signal lines produce interference.

Away from vibration, foreign object impact: high-voltage wire harnesses in the arrangement of the possibility of passing through the body sheet metal holes, so the existence of high-voltage wire harnesses over the sheet metal holes or cut with the sheet metal need to use rubber parts for protection, on the one hand, to avoid direct contact between the sheet metal and wire harness damage, on the other hand, to reduce the noise brought about by vehicle vibration.

Consider the bending radius and stress concentration problems: high-voltage cable wire diameter is thicker, in the car in a small space for the arrangement, to consider the high-voltage cable over the bend, the impact of its bending radius. Usually the bending radius should be greater than 5 times the diameter.

Away from the pipeline: In order to ensure the safety of the electrical system, the arrangement should be far away from the coolant, washing liquid, oil and other pipelines, to avoid leakage along the high-voltage harness into the electrical parts, so the high-voltage harness in the arrangement to be slightly higher than the pipeline.

Summary: high-voltage wiring harness as an important connection parts of hybrid vehicles, its reliability, safety is vital to the safety of the vehicle, so in the selection of cable to fully consider the selection of parts to avoid over-designed surplus, while in the cable selection and fixed, protective material selection, to consider the weight of the harness, as far as possible to reduce weight and save costs.

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