The Manual Service Disconnect (MSD) serves as a critical safety device in electric vehicle and new energy high-voltage systems, providing protection against short circuits and overloads during maintenance. MSDs incorporate high-voltage fuses and interlock functions to ensure operational safety. Key performance criteria include UL94 V-0 flame resistance, IP67/IP6K9K ingress protection, tool-free manual disconnection, and a locking mechanism to prevent misoperation.

As electric vehicles continue to gain traction worldwide, ensuring the reliability of high-voltage components becomes a central focus of vehicle design. Among these, high-voltage cables serve as the critical arteries for energy transmission. This article presents a comparative analysis of various shielding structures used in high-voltage cables and highlights a new design—an extruded semi-conductive layer combined with tinned copper braid shielding. The new structure significantly improves cable lifespan and shielding performance without compromising flexibility or increasing production costs.

High-voltage wiring harnesses play a crucial role in powering and protecting key systems within electric vehicles. However, faults in these systems can result in safety hazards, vehicle malfunction, or even catastrophic damage. This article outlines four critical methods to prevent HV wiring harness failures: designing application-specific harnesses, ensuring component compatibility, selecting high-quality materials for demanding environments, and eliminating crimping or soldering issues. By addressing these areas, OEMs and harness manufacturers can ensure safe, reliable, and long-lasting EV performance.

The wire harness industry, integral to sectors like automotive, communications, and industrial manufacturing, is embracing rapid technological advancements. Innovations in AI and automation are improving design precision and manufacturing efficiency.

Unlike conventional cables, EV high-voltage cables must withstand extreme temperatures (up to 175°C in some cases) and transmit high currents (up to 450A). Common insulation materials such as XLPE, silicone rubber (SIR), and thermoplastic elastomers (TPE) are selected based on their temperature resistance, flexibility, and mechanical properties.

HV wiring harnesses are critical components in EVs, ensuring safe and reliable power distribution. These harnesses undergo rigorous testing to meet stringent industry standards and guarantee performance in various conditions. Key tests include electrical performance checks such as dielectric withstand, continuity, and insulation resistance; mechanical durability assessments like tensile strength and vibration resistance; and environmental tests, including temperature cycling and humidity resistance. Additionally, tests for EMI and HVIL safety features are essential for ensuring safety. This comprehensive testing process is crucial for the durability, safety, and compliance of EVs, particularly in the challenging automotive and energy environments.