78

1

Hybrid Electric VehicleHEVElectric VehicleEVHEVEV

2

21 1990

1990 12 V

5 10

2005 2009 1

1

1

Wiring harnesses for Next Generation Automobiles

K. Oba

CO2 Hybrid Electric VehicleHEVElectric VehicleEV 1 30 kg30 %

The weight of a wiring harness is increasing year by year because of newly added functions. In recent years, there are growing customer demands for environmentally friendly products, such as high -voltage wiring harness systems for Hybrid Electric Vehicles (HEVs) and Electric Vehicles (EVs), and weight - saving wiring harnesses de-signed to improve fuel eff iciency.

In order to satisfy these customer demands, we are developing a high -voltage wiring harness system and weight - saving electric wire and connection technology for a weight - saving wiring harness system.

Although the gross weight of the wiring harness using a conventional electric wire is about 30 kg/car, weight saving of about 30 % is possible by using a weight - saving electric wire.

1Fig. 1. Plug - in STELLA.

79

2 3 1

2010

2011 4 5

HEV Hybrid Electric Vehicle

EV Electric Vehicle

Junction Box

WH Wiring Harness ASSY

CA Copper Clad Aluminum

DC/DC

DC

DCAC

2Fig. 2. System outline.

WH

DCWH

ACWH

3Fig. 3. High -voltage wiring harness.

4Fig. 4. Full f lat f loor electric bus.

5Fig. 5. High voltage cable.

2012 Vol. 2 123

80

22

FHVC-Mark FHVC-MarkFHVC-S 1

6 72

600 V 98 kPa 40 dB

FHVC-MarkFHVC-S

15 20 sqmm2 8 3 5 sq 9, 2

8FHVC-MarkFig. 8. FHVC-Mark Under Development

9FHVC-SFig. 9. FHVC-S.

6FHVC-Mark IFig. 6. FHVC-Mark I Connector type

7FHVC-Mark Fig. 7. FHVC-Mark I Bolt - on type

3

81

3

AVAVSAVSSCAVUS CHFUSCIVUS 2 3 Copper clad AluminumCA 1 / 4 1 312 .5 sqmm2

140 Mpa10 % 58 % 2

10 32CA2.5 sq

CACA 11 0.18 mmCA

10Fig. 10. Cross section of Aluminum alloy wire.

Cu

Al

11CAFig. 11. Cross section of CA wire.

MPa

%

% IACS

140 10 58 145 .9 13 59 .4

2Table 2. Characteristics of aluminum alloy wire.

sqmm2

sqmm2

0.13 0 .08 0.5 2 0 .75 2 3 5 100 CA

1Table 1. Current wire and suitable

light weight electric wire size

2012 Vol. 2 123

82

12 CA33

0.13 sq

0.3 sq 0.13 sq 0.08 sq 0.3 sq

4

30 kg 30 %

1 FHVC-Mark119p. 532010

2 0.13 mm2 119p. 522010

12CAFig. 12. Cross section of CA wire terminal.