Catia V5 - Electric Vehicle High Voltage Harness Design

Compare electric and ice vehicles by examining mid-mounted motors, traction battery placement, high-voltage harnesses, and the role of onboard chargers, DC-DC converters, and motor inverters.

Explore electric vehicle high voltage harnesses, their orange color coding, and how battery packs connect through the junction box to inverters, DC-DC converters, and the on-board charger.

Explore the differences between HEV, MHEV, PHEV, and BEV, from 48V mild hybrids to full battery electric vehicles, including high voltage systems, inverters, and the traction battery.

Explore high voltage connectors for electric vehicles, including three-, two-, and one-pole designs with 1000v ratings, IP67/IP69K protection, high voltage interlocks, and crimp or screw terminations.

Understand how to select ev high-voltage connectors by sizing current, choosing wire CSA, and evaluating interlocks, 3D space, and part numbers using supplier data, CAD models, and datasheets.

Analyze high voltage cables for EVs and hybrids, choosing bare copper or aluminum, shielded or unshielded, and single or multi-core, with current, voltage drop, and diameter considerations for Catia V5.

Explain how orange protection materials secure high voltage harnesses in the under body and front end, using corrugated tubes, tapes, and orange plastic channels, with bending constraints and real-world testing.

Explore the traction battery structure, detailing cells, modules, busbars, and the battery management system, plus high and low voltage harnesses and interlocks that ensure safe charging and discharging.

Explore how battery cells form a high voltage module with busbars connecting the poles, inter-cell connections, and temperature sensors managed by the BMS, shaping overall pack volume and performance.

Examine how the cell supervisory module integrates with the bms to collect voltage and temperature data from each module via canbus, reducing harness wiring by about 70%.

Understand how the battery management system monitors cell temperatures and voltages, balances cells, estimates state of charge and health, and interfaces with vehicle harnesses and modules.

Explore how the battery electric control module sits between high voltage busbars and external connectors, housing fuses, a current sense sensor, and high voltage contactors controlled by the BMS.

Learn how the orange low voltage harness interconnects battery modules to the BMS while avoiding high voltage paths, and how CSC-based module placement optimizes routing.

Prepare the three-dimensional CAD model by inserting two high voltage connectors, aligning their axes and contact surfaces, and planning the cable route without modifying existing parts.

Electrify the two high-voltage connectors by defining bundle connection points and a three-termination harness between the front connector and the on-board charger, using orange multi-core cable and convoluted tube protection.

Populate the 3d model with bundles by designing and electrifying clips, defining support planes, and routing a high voltage charger harness using multi-branch cable routing and bend radius constraints.

Review harness routing by adding slack to each segment, ensure 25 mm fluid-pipe clearance and clip rotation, and verify wheel-arch liner clearances with PLM tools.

Resolve the 14 mm clearance issue for the harness by replacing the corrugated section with a rigid Delfin tube, ensuring exact length, anti-rotation fixes, and a documented deviation sign-off.

Finish routing the high voltage harness in the plastic channel using a mid-plane spline with tangency and control points, threading the bundle along an external curve with slack.

Explore tolerances in harness manufacturing, assess worst-case length increases, and design with extra length, branches, and clearances. Plan emi considerations, ferrites, and comprehensive cad documentation and assignments.

Electrify high-voltage connectors by setting bundle connection points in catia v5, color them orange, and assign three points, two points, or one point per connector for multi-wire cables.

Prepare the Catia V5 EV high voltage harness project by opening, saving, and copying parts, then position front and rear high voltage connectors using guides and shading for smooth assembly.

Create and organize the file infrastructure for Catia V5 high voltage harness design, defining front and rear motor and inverter harnesses, junction box, and multi-branch documents.

Design a double cable retainer for an electric vehicle high-voltage harness in Catia V5, placing planes 1.5 mm from the surface, saving the project, and noting optional cable ties.

Design the front motor high-voltage harness in Catia v5, modeling three 13 mm cables from inverter to motor with four times diameter bend radii, planning bracket fixings and routing.

Design the front inverter high voltage harness from the battery to the inverter, routing two cables through the high voltage tray with clips and accurate bend radii.

Design and route the high voltage junction box harness, connecting the ancillary connector, high voltage heater, charger, and DC-DC converter.

Route the motor to inverter high voltage harness via the shortest path, above or under the motor, using a plastic channel that accommodates bend radii and slack.

Route rear inverter harness from the battery connector to the inverter through a plastic channel and grommet, fixed to the control unit bracket and subframe, ensuring tangency and bend radius.

Align fixings and modify the high voltage harness design for the EV powertrain, ensuring proper slack, clip placement, and connector alignment while exploring portfolio-worthy routing variations.

Place all electrified components, connectors, retainers, and plastic channels inside the harness product using the geometrical bundle to assign electrical properties, avoiding cross-product connections to prevent Catia V5 errors.

Design and fill plastic channels with cables for a vehicle harness, including connectors, wires, grommets, and cable ties. Evaluate bend radius, slack, and clashes using curves, splines, and planes.

Design an internal traction battery harness by wiring battery modules with busbars, integrating BMS supervision, temperature sensors, and low- and high-voltage connections, using CSC wiring and module matrix optimizations.

Learn how to map low-voltage harness connectivity for a traction battery, assign modules to CSCs, create pinouts and connector rules, and plan bundle diameters using Catia V5.

In Catia V5, calculate bundle diameters for five-pin module connectors and seventeen-pin CSC connectors, position wires and connectors, and begin the high voltage harness assembly.

Electrify connectors and start the harness design by defining CSC connectors, setting terminations, creating a geometrical bundle, and routing wires with branch points and fixings.

Calculate bundle diameters for added wires, design the first retainers and a plastic channel to guide the harness, and copy the setup five more times across fixings.

Design and populate the high-voltage harness by adding branches and branch points, enforcing 30mm/50mm spacing, tangency rules, and color-coded module bundles, with save management.

Position a custom retainer for the battery harness with two fir trees for anti-rotation, align center about 20 mm from edge, and mirror across beams using symmetry and middle plane.

Design the main bundles for the Catia v5 electric vehicle high voltage harness by defining support planes, placing retainers, and routing nine millimetre bundles with branch points and tangency, while considering possible clashes and manufacturing constraints.

Model a symmetrical high-voltage harness for the battery pack, route six branches to the front connector, and cover the H connection concept and bracket features, including threaded holes.

Align the rear battery plastic channel with the battery, keep holes clear, and route the main bundle using retainers, fixings, and tangency points toward CSCs and the BMS.

Route the BMS connector into the harness, define the bundle connection point, and align wires to the CSC while coordinating retainers, holes, slack, and bend radii.

Finish the high voltage harness by optimizing bundle connections, routing wires to modules without creating loops, checking branching points, slack, diameters, and DFM considerations for safe, manufacturable design.

Update bundle diameters across the high-voltage harness, applying 5.5 mm from module connectors and 9 mm from CSC connectors, with an Excel table mapping wire counts to diameters.

Solve bend radius issues by updating bundle diameters and calculating slack for the wires across modules, CSIs, and the BMS in a Catia V5 electric vehicle harness.

Add local slack to each bundle to allow smooth bends, measure branch point lengths, and align with production rules for fixed, five-millimeter increments, while saving frequently.

Fill the plastic channel in the traction battery harness with wire bundles, calculate the maximum cross-sectional area, and shape the bundle using square profiles and branching points for realism.

Learn how the high voltage interlock (HVIL) detects when the high voltage connector is pulled, signaling the BMS to disconnect the battery via contactors for safety.