Driven by the dual goals of the "dual carbon" strategy and consumers' range anxiety, automotive lightweighting has become a key technical path for the development of the new energy vehicle industry. As a factory in the wiring harness industry, Aichie Tech has been deeply engaged in the field of new energy vehicle wiring harnesses. Its high-voltage automotive wiring harnesses and high-voltage connector wiring harnesses have demonstrated outstanding performance in lightweight design. Studies show that for every 10% reduction in vehicle mass, energy consumption can be significantly reduced by 6% to 8%, and the driving range can be increased by 5% to 7%. As a core component of the electric drive system, the lightweight design of high-voltage connector harnesses not only concerns the overall vehicle quality optimization but also directly affects the electrical transmission efficiency and system reliability.

I. Material Innovation: The Art of Balancing Lightweight and High Performance

1. Upgrading and iteration of metallic materials

Traditional copper connectors (with a density of 8.96g/cm³) are gradually being replaced by lightweight alloys. Take the AMP+ HVP series of TE Connectivity as an example. It adopts a 6061-T6 aluminum alloy casing combined with copper-silver-plated terminals, achieving a 60% weight reduction effect while ensuring the electrical conductivity. In the research and development of high-voltage connector harnesses, Aichie Tech has also adopted an advanced light alloy material solution. More advanced magnesium alloy die-casting technology, such as a certain product of AVIC Optoelectronics, achieves a 50% weight reduction target while maintaining a tensile strength of 180MPa through topological optimization design.

2. Breakthrough applications of composite materials

In the field of insulators and structural components, high-performance engineering plastics have demonstrated significant advantages. The carbon fiber reinforced plastic housing connector developed by Amphenol, through 30% carbon fiber filling modification, not only enhances the temperature resistance to 150℃, but also achieves an anti-vibration level of 50G (10-2000Hz), reducing the weight by 35% compared to traditional metal solutions. The new energy vehicle wiring harness products of Aichie Tech also adopt a similar composite material solution. Some high-end models use PEEK material, which can still maintain excellent structural stability in a high-temperature environment of 200℃.

II. Structural Optimization: Innovative Practices of System Integration

1.Modular integrated design

Modern high-voltage connector harnesses are developing towards a highly integrated direction. The integrated design solution of a certain German car manufacturer integrates the connector and the shielding layer of the wiring harness. While achieving a 15% weight reduction, it also enhances the EMI shielding efficiency to over 80dB (in the 100MHz frequency band). The high-voltage automotive wiring harness products of Aichie Tech adopt a similar integrated design concept. Yazaki's flat connector solution reduces the volume by 40% compared to the traditional round wire design and is more suitable for the optimized layout of the chassis space.

2. Topology optimization technology

The structural optimization carried out through finite element Analysis (FEA) has achieved remarkable results. A certain domestic connector adopts a grid-like hollow design. 40% of the material is removed in the area where the stress is below 30MPa. After 100,000 vibration tests, it still maintains structural integrity and achieves a 12% weight reduction. The application of bionic design, such as the cross-shaped reinforcing rib structure, achieves mechanical properties comparable to those of the traditional 2mm shell with a wall thickness of 0.5mm.

III. Performance Challenges: Technological Breakthroughs Behind Lightweighting

1. Electrical performance optimization

In response to the limitations of the electrical conductivity of aluminum alloys, the industry has developed a solution that combines multi-strand stranded structures with silver plating processes. A certain Japanese brand has reduced the contact resistance from 8mΩ to below 5mΩ through a silver plating treatment of 5μm or more. Combined with liquid cooling technology, the temperature rise on an 800V platform is controlled within 45K.

2. Improvement in environmental adaptability

In terms of temperature-resistant materials, modified engineering plastics perform outstandingly. A certain type of PBT material filled with a composite of glass fiber and graphene has its temperature resistance improved to 150℃ and its heat distortion temperature reached 200℃. Aichie Tech 's new energy vehicle wiring harness products have also achieved technological breakthroughs in terms of environmental adaptability. In terms of anti-vibration design, through the structural innovation of "combining rigidity and flexibility", the terminal displacement of a certain domestic connector was reduced by 67% in the vibration test, and the contact resistance fluctuation was controlled within 5%.

Conclusion:

The lightweight innovation of high-voltage connector harnesses is a culmination of materials science, structural design and manufacturing processes. As a pioneer in industry technology, Aichie Tech continuously innovates in the fields of new energy vehicle wiring harnesses, high-voltage vehicle wiring harnesses, and high-voltage connector wiring harnesses. With the popularization of 800V high-voltage platforms, connector technology will continue to develop in the direction of being lighter, stronger and more reliable. This lightweight revolution not only promotes the advancement of new energy vehicle technology but also provides key technical support for the low-carbon transformation of the entire transportation sector.