CN219833260U

CN219833260U - Wire harness assembly for charging power and electric automobile comprising same

Info

Publication number: CN219833260U
Application number: CN202320304331.9U
Authority: CN
Inventors: 阙丁祥; 帅希士; 祝一帆
Original assignee: Weilai Automobile Technology Anhui Co Ltd
Current assignee: Weilai Automobile Technology Anhui Co Ltd
Priority date: 2023-02-21
Filing date: 2023-02-21
Publication date: 2023-10-13
Anticipated expiration: 2033-02-21

Abstract

The utility model discloses a wire harness assembly for charging and power distribution and an electric automobile comprising the wire harness assembly. The wire harness assembly is connected between a first connection point and a second connection point, characterized in that the wire harness assembly comprises: an aluminum conductor; and a transit structure through which the aluminum conductor is connected to the first or second connection point, the transit structure being configured as a copper terminal, the copper terminal and the aluminum conductor being connected by welding, the copper terminal and the first or second connection point being connected by a fastener. The utility model can meet the requirement of large current, and the whole weight and cost of the wire harness are not increased.

Description

Wire harness assembly for charging power and electric automobile comprising same

Technical Field

The utility model relates to the field of cable design, in particular to a wire harness assembly for charging or power distribution.

The utility model also relates to an electric automobile comprising the wire harness assembly.

Background

The wires are an important component of the harness and represent 30% of the harness cost. The conventional conductor materials of the current lead are pure copper, copper alloy, aluminum and the like, wherein the conductivity ratio of copper to aluminum is 1:0.629, the price ratio of copper to aluminum is 1:0.4, and the density ratio of copper to aluminum is 1:0.3, so that the aluminum lead has the advantages of performance, price and quality, and is an ideal substitute material for copper core leads.

In the electric automotive industry, copper is used as the primary wire material. However, the price of copper wires is rising, charging current is larger and larger, and higher requirements are put on the current carrying capacity and cost and weight reduction of the wire harness.

Disclosure of Invention

One aspect of the present utility model is to provide a harness assembly for charging power that further provides a solution for using aluminum instead of copper wire.

The wire harness assembly is connected between a first connection point and a second connection point, the wire harness assembly comprising: an aluminum conductor; and a transit structure through which the aluminum conductor is connected to the first or second connection point, the transit structure being configured as a copper terminal, the copper terminal and the aluminum conductor being connected by welding, the copper terminal and the first or second connection point being connected by a fastener.

In one embodiment of the wire harness assembly, the aluminum conductor is configured as an aluminum bar wire having a rectangular cross-sectional shape.

In one embodiment of the wire harness assembly, the aluminum bar wire is further configured to include a cell, an insulating layer covering the cell, and a shielding layer covering the insulating layer.

In one embodiment of the wire harness assembly, one of the first connection point and the second connection point is configured as a charging terminal, and the other is configured as a connection terminal for a battery system.

In one embodiment of the harness assembly, the charging terminal is a charging receptacle; the connecting end is a connector, wherein the wiring direction of the aluminum conductor and the copper terminal is perpendicular to the terminal direction of the connector.

In one embodiment of the harness assembly, a shielding device is disposed within the charging receptacle or the connector between the aluminum conductor and a housing for the charging receptacle or the connector.

In one embodiment of the wire harness assembly, the shielding device is configured as a coil disposed about the aluminum conductor.

In one embodiment of the harness assembly, the fastener is configured to provide a threaded connection between the copper terminal and the respective terminal of the charging socket or the connector.

In one embodiment of the wire harness assembly, in the charging socket, a side portion of a terminal of the charging socket is configured as a first flat surface, the first flat surface and the copper terminal being stacked on each other and connected by a screw; or in the connector, an end portion of a terminal of the connector is configured as a second flat surface, the second flat surface and the copper terminal being stacked on each other and connected by a screw.

The wire harness assembly of the present utility model uses an aluminum conductor instead of copper, and the ends of the aluminum conductor are routed to copper terminals so that the aluminum conductor can be connected between the first connection point and the second connection point. The use of aluminum material can meet high current requirements and does not increase the overall weight and cost of the harness.

Aluminum conductors use aluminum bar wires. Compared with the traditional copper wire, the aluminum bar is used as the main conductor, and the aluminum bar has smaller space, lighter weight and lower cost. The aluminum bar is used as a rigid conductor, and the scheme of switching the copper terminal can solve the problem of mounting tolerance.

In one embodiment, the first connection point and the second connection point are a charging receptacle and a connector for connection of a battery system, respectively. The shielding device can be provided for the switching structure in the charging socket or the connector, so that shielding protection of the whole section of cable between two connection points is ensured, and EMC (electro magnetic compatibility) problems are avoided.

Another aspect of the present utility model is to provide an electric vehicle including the wire harness assembly of any one of the above embodiments.

The electric automobile can provide high-current charging or power distribution requirements due to the arrangement of the wire harness assembly, and has lighter weight, lower cost, easier assembly of the wire harness and reliable EMC design under the condition of the same current carrying.

Other aspects and features of the present utility model will become apparent from the following detailed description, which refers to the accompanying drawings. It is to be understood that the drawings are designed solely for purposes of illustration and not as a definition of the limits of the utility model, for which reference should be made to the appended claims. It should be further understood that the drawings are merely intended to conceptually illustrate the structures and procedures described herein and that, unless otherwise indicated, the drawings are not necessarily drawn to scale.

Drawings

The present utility model will be more fully understood from the following detailed description of the specific embodiments, taken in conjunction with the accompanying drawings, in which like reference numerals refer to like elements throughout the views. Wherein:

FIG. 1 illustrates a schematic view of one embodiment of a wiring harness assembly in accordance with the present utility model;

FIG. 2 is a schematic view showing the internal structure of the connection of the charging jack to the wire harness assembly according to the present utility model; and

fig. 3 is a schematic view showing an internal structure of the connection of the connector to the wire harness assembly according to the present utility model.

Detailed Description

In order to assist those skilled in the art in precisely understanding the subject matter claimed herein, a detailed description of the utility model is provided below in connection with the accompanying drawings.

Fig. 1 shows a schematic view of one embodiment of a harness assembly in accordance with the present utility model. In one application, the harness assembly is for a charging cable of a vehicle. As shown, the harness assembly 10 is connected between a first connection point 20 and a second connection point 30, wherein the first connection point 20 is a charging terminal and the second connection point 30 is a connection terminal (or IPU terminal) for a battery system. The charging terminal may be a charging socket and the connection terminal may be a connector, as will be described below. The wire harness assembly according to the present utility model may also be used in other high voltage or high current cable applications such as, but not limited to, power distribution services.

Fig. 2 is a schematic view showing an internal structure of the connection of the charging socket to the wire harness assembly according to the present utility model. The charging socket 21 includes a housing 23 in which terminals 25 of the charging socket are disposed. The harness assembly 10 is oriented in the same direction as the terminals 25 of the charging jack. Fig. 2 shows that the charging socket includes two terminals having the same configuration. A harness assembly 10 is connected to a terminal 25 of a charging jack. The wire harness assembly 10 includes an aluminum conductor and a transition structure. The aluminum conductor is configured as an aluminum bar wire 110 having a rectangular cross section, and includes a cell 12, an insulating layer 13 covering the cell 12, and a shielding layer 14 covering the insulating layer 13. The switching structure is configured as a copper terminal 15. The aluminum bar wire 110 and the copper terminal 15 are welded, as shown by the welding position "16" in the figure. The copper terminal 15 is connected to the terminal 25 of the charging socket by a fastener 27. Fastener 27 provides a threaded connection for copper terminal 15 and terminal 25 of the charging receptacle. In the illustrated embodiment, the fasteners 27 are configured as screws. The side of the terminal 25 of the charging socket is configured as a first flat surface 251, the first flat surface 251 and the copper terminal 15 are stacked on each other, and a screw passes through the copper terminal 15 and the first flat surface 251 to fasten them. The terminals 25 of the charging socket are pre-processed to form a first flat surface 251 and are offset from the center of the terminal block, leaving room for the copper terminals 15 to be mounted. The charging socket 21 further includes a tail cap 28. At the tail cap 28, a seal ring 29 is provided between the wire harness assembly 10 and the tail cap 28.

Fig. 3 is a schematic view showing an internal structure of the connection of the connector to the wire harness assembly according to the present utility model. The connector 31 includes a housing 33 in which terminals 35 of the connector are disposed. The harness assembly 10 runs perpendicular to the terminals 35 of the connector. The harness assembly 10 is connected to the terminals 35 of the connector. The wire harness assembly in fig. 3 has the same configuration as that of fig. 2, and the configuration of the wire harness assembly is not repeated here, and like reference numerals in fig. 3 denote like elements as in fig. 2. In the illustrated embodiment, the copper terminals 15 are connected to the terminals 35 of the connector by fasteners 37, i.e., screws. Unlike the structure of fig. 2, the end portions of the terminals 35 of the connector, i.e., the top portions shown in the drawing, are configured as second flat surfaces 351, which are stacked on each other with the copper terminals 15 protruding into the housing, and screws pass through the copper terminals 15 and the second flat surfaces 351 to fasten them. The terminal 35 ends of the connector are machined with a second planar surface 351 to engage the copper terminals 15. Similarly, the connector 31 also includes a tail cap 38. At the tail cap 38, a seal 39 is provided between the wire harness assembly 10 and the tail cap 38.

Additionally, in the illustrated embodiment, a shielding device 40 is provided between the wire harness assembly 10 and the housing 33 to provide electromagnetic shielding protection. The shielding means 40 is configured as a spring coil, one end of which is connected to the housing 33 and the other end of which is connected to the shielding layer 14 of the aluminium bar conductor 110. The spring ring can provide good retention force for both ends thereof to ensure shielding performance of the wire harness assembly. In addition to being disposed within the connector as shown in fig. 3, the shielding device may also be disposed within the charging receptacle.

The utility model also relates to an electric automobile, wherein the wire harness assembly described in any embodiment is connected between a charging socket and a battery system of the electric automobile.

While specific embodiments of the utility model have been shown and described in detail to illustrate the principles of the utility model, it will be understood that the utility model may be embodied otherwise without departing from such principles.

Claims

1. A wire harness assembly (10) for charging power, the wire harness assembly being connected between a first connection point (20) and a second connection point (30), characterized in that the wire harness assembly (10) comprises:

an aluminum conductor (11); and

-a transfer structure, via which the aluminium conductor (11) is connected to the first connection point (20) or the second connection point (30), the transfer structure being configured as a copper terminal (15), the copper terminal (15) and the aluminium conductor (11) being welded, the copper terminal (15) and the first connection point (20) or the second connection point (30) being connected by means of a fastener.

2. The wire harness assembly (10) according to claim 1, wherein: the aluminum conductor (11) is configured as an aluminum bar wire (110) having a rectangular cross-sectional shape.

3. The wire harness assembly (10) according to claim 2, wherein: the aluminum bar wire (110) is further configured to include a battery cell (12), an insulating layer (13) covering the battery cell (12), and a shielding layer (14) covering the insulating layer (13).

4. The wire harness assembly (10) according to claim 1, wherein: one of the first connection point (20) and the second connection point (30) is configured as a charging terminal, and the other is configured as a connection terminal for a battery system.

5. The wire harness assembly (10) according to claim 4, wherein: the charging terminal is a charging socket (21); the connecting end is a connector (31), wherein the wiring direction of the aluminum conductor (11) and the copper terminal (15) is perpendicular to the terminal direction of the connector (31).

6. The wire harness assembly of claim 5, wherein: a shielding device (40) between the aluminum conductor (11) and a housing for the charging socket (21) or the connector (31) is arranged in the charging socket (21) or the connector (31).

7. The wire harness assembly of claim 6, wherein: the shielding device (40) is configured as a coil arranged around the aluminum conductor (11).

8. The wire harness assembly of claim 5, wherein: the fastener is configured to provide a threaded connection between the copper terminal (15) and the respective terminal of the charging socket (21) or the connector (31).

9. The wire harness assembly of claim 8, wherein: within the charging socket (21), the sides of the terminals (25) of the charging socket are configured as first flat surfaces (251), the first flat surfaces (251) and the copper terminals (15) being stacked on each other and connected by screws; or (b)

Within the connector (31), an end portion of a terminal (35) of the connector is configured as a second flat surface (351), and the second flat surface (351) and the copper terminal (15) are stacked on each other and connected by a screw.

10. An electric vehicle characterized by comprising a harness assembly (10) for charging electric power according to any one of claims 1-9.