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New Energy Vehicle Wire Harness Electric Energy Storage Cable

New Energy Vehicle Wire Harness Electric Energy Storage Cable

This high-voltage heavy-duty terminal harness is specially developed for new energy passenger vehicles, commercial EVs, lithium energy storage systems and industrial automation high-power power distribution modules. It adopts industry-standard orange high-voltage silicone insulated wire with braided flame-retardant protective sleeve, equipped with automotive-grade orange plastic high-voltage interlock connector (HVIL) on one end and customized stamped copper crimp lugs on the other. The integrated HVIL high-voltage interlock safety structure automatically cuts off high voltage when the connector is pulled apart to prevent electric arc hazards, while thick tinned copper terminal lugs provide ultra-low resistance stable heavy-current transmission. All materials comply with automotive LV-216 high-voltage standards, flame retardant, oil resistant and wide temperature resistant. Customizable wire cross-section, lug bending shape, connector pin count and total length are supported, widely applied to EV battery pack internal connection, vehicle PDU power distribution box wiring, household/commercial energy storage battery modules and industrial high-power automation equipment power loops.

Model:
New energy vehicle cable
Brand:
huamao

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New energy vehicle cable high current terminal cable high power terminal wire high voltage wire automotive wiring harness

Product Description

The HVIL interlock connector is the core safety feature of new energy vehicles, solving the hidden danger of electric shock and arc ignition caused by accidental disconnection of live high-voltage circuits. The double-layer orange silicone high-voltage wire withstands continuous high temperature inside the battery compartment, resistant to electrolyte corrosion, engine oil splash and long-term vehicle vibration aging. The external woven braided sleeve enhances abrasion resistance to avoid insulation damage from friction with metal brackets inside the vehicle chassis. Thickened copper lugs reduce contact resistance and suppress excessive temperature rise under peak discharge current of EV acceleration and energy storage charging/discharging cycles. All crimp and connector transition positions are wrapped with high-voltage heat shrink tubing for secondary insulation reinforcement.

Every finished high-voltage harness passes strict factory safety testing before shipment, including high voltage withstand test, continuous heavy-current temperature rise test, vehicle vibration aging screening, flame retardant combustion test and HVIL interlock function verification. We supply fixed-length battery internal connection wires and customized multi-specification high-power terminal harnesses for new energy vehicle OEM manufacturers, energy storage system integrators and industrial automation high-power equipment factories.

Advantages

HVIL high-voltage interlock safety protection system: Built-in detection pin realizes power-off interlock logic, avoids dangerous high-voltage electric arcs when disassembling the harness, fundamentally eliminates electric shock and fire hidden dangers during vehicle maintenance and energy storage equipment overhaul, meeting mandatory new energy vehicle safety regulatory requirements.
Distinctive orange double-layer high-voltage silicone wire: Industry standard orange warning color to remind operators of high-voltage hazards; double silicone insulation has excellent high voltage resistance, heat resistance and electrolyte corrosion resistance, far more reliable than ordinary PVC power wires for EV battery compartment closed high-temperature environments.
Hydraulic integrated crimp thick copper terminal lugs: Full tin-plated thick copper lugs with customized bending geometry fit battery copper bar and PDU mounting layout perfectly; large crimp contact area reduces loop resistance and effectively controls temperature rise under peak acceleration heavy current of new energy vehicles.
External aramid woven flame retardant abrasion sleeve: Effectively prevent insulation layer wear and breakage caused by long-term friction between the harness and vehicle metal brackets, the woven material also blocks flame spread in case of accidental short circuit, improving overall system fire safety performance.
All-scenario wide compatibility for EV & energy storage: Adaptable to passenger car power battery internal wiring, commercial vehicle high-voltage PDU distribution box connection, household outdoor energy storage lithium battery module power loops and industrial automation high-power servo equipment main power supply wiring.
Automotive-grade full customized service: Support ultra-short built-in battery internal short jumpers and 10m long-distance chassis high-voltage extension cables, small batch prototype sample orders available for new energy vehicle and energy storage system new product development verification.

Application

Passenger New Energy Electric Vehicles:EV power battery pack internal high-voltage connection harness, vehicle PDU power distribution box HVIL terminal cable, electric vehicle air conditioning compressor high-power power wire, on-board OBC charger input high-voltage assembly
Commercial Electric Vehicles & Heavy-Duty Trucks:Electric bus battery pack heavy-current terminal wiring harness, new energy logistics truck motor controller high-voltage cable, construction electric vehicle energy storage power interlock connecting wire
Household & Commercial Lithium Energy Storage Systems:Wall-mounted home energy storage battery module high-voltage terminal wire, commercial industrial energy storage cabinet power distribution harness, outdoor portable large-capacity energy storage station HVIL interlock cable
Industrial Automation High-Power Equipment:Large industrial servo motor main power heavy-current wiring harness, automated production line high-power inverter input high-voltage terminal cable, energy storage test bench battery connection interlock wire
Off-Road EV & Special New Energy Equipment:Electric forklift lithium battery high-voltage interlock harness, sightseeing electric vehicle power battery terminal cable, mining explosion-proof new energy equipment customized high-voltage wiring assembly

FAQ

Q1: What is the core safety function of the orange HVIL connector on this harness?

A: The built-in high-voltage interlock detection pin will trigger the vehicle BMS to disconnect the high-voltage relay first when the connector is about to separate, cutting off the main power circuit in advance to avoid dangerous electric arcs and electric shock hazards during live disassembly.

Q2: Why must new energy high-voltage cables use orange insulation?

A: Orange is the unified industry mandatory warning color for all DC high-voltage circuits of new energy vehicles and energy storage equipment, to quickly remind maintenance personnel of high-voltage hazard identification, distinguishing from 12V low-voltage black wiring harnesses.

Q3: Can this harness withstand long-term high temperature inside the EV battery compartment?

A: Double-layer silicone insulation supports continuous stable operation up to 150℃, resistant to heat accumulation during battery charging and discharging, will not harden, crack or lose insulation performance after years of vehicle operation.

Q4: Is the crimp between the copper terminal lug and the wire core loose easily under vehicle vibration?

A: Adopts full hydraulic integrated crimp process with large contact compression area, passed 500-hour road simulation vehicle vibration test, no terminal shedding or increased contact resistance after long-term driving vibration.