Catia V5 - Electric Vehicle High Voltage Harness Design

Name: Catia V5 - Electric Vehicle High Voltage Harness Design
Rating: 4.7 (289 reviews)

Learn HV harness design for electric vehicles from an engineer with more than 18 years experience in the design industry

Created byAlexander Consulting

Last updated 9/2023

English

What you'll learn

Learn how to design high voltage electrical wiring harnesses like you would be working on a real job in a company
Learn about the structure of an electrical vehicle
Learn about the structure of an EV traction battery
Learn about HV harness components and the basics of selecting them
We design a few HV Harness projects together
We design the internal harness for a EV traction battery
I provide CAD files for each project
I design with Catia V5 but you can design the projects with any CAD software

Course content

6 sections • 54 lectures • 10h 34m total length

A quick about me1:23
Add subtitles in your own language3:52
Learn to add subtitles in your language for Udemy videos using a Chrome/Brave extension that translates English captions into Hindi and Spanish, with adjustable font size and colors.
What do you need to take this course7:21
Using resource files2:45

Electric vehicle structure11:53
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.
Electric vehicle high voltage harness16:04
The difference between: HEV, MHEV, PHEV and BEV14:58
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.
High voltage connectors for EV applications12:25
EV high voltage connector selection basics11:47
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.
High voltage cables for EV applications9:17
EV high voltage cables selection basics5:20
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.
Protection materials for EV high voltage electrical harnesses5:12

Electrify HV connectors6:53
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.
Preparing the project and positioning connectors15:22
Creating file infrastructure for the projects6:09
Electrify HV retainer2:09
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.
Front EDU HV harness design12:35
Front inverter HV harness design17:04
HV junction box harness design14:25
Rear EDU HV harness design19:28
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.
Rear inverter HV harness design8:28
Final adjustments and portfolio design ideas27:08
Organize harnesses9:28
Designing wires in channels10:46

Traction battery harness design project9:05
Harness connectivity and calculations19:02
Calculating bundles and starting the assembly22:46
Electrify connectors and start the harness design13:14
Defining the first retainers for the bundles19:16
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.
Populate the harness with branches22:35
Retainer assignment2:27
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.
Designing the main bundles19:32
New assignments3:39
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.
Design the rear bundles12:53
Routing the BMS14:43
Finishing the bundle connections16:49
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.
Updating bundle diameters9:59
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.
Solving bend radius issues and updating last diameters18:14
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.
Adding slack to the bundles13:45
Filling channels with wires18:19
HVIL - High Voltage Inter-Lock31:52

Requirements

To do this course you need to know how to use Catia V5 Electrical Part Design/Assembly and Catia V5 Electrical Harness Design/Installation
You need to have Catia V5 installed

Description

My name is Alex, and I am a Design Engineer.

I have been working for more than 18 years with Catia V5 in automotive engineering, racing and industrial design.

All the knowledge and experience that I gained helped me work with companies like: Ferrari Formula One Team, Red Bull Racing, Jaguar Land Rover, Aston Martin and others

In this course I will show you how to design HV electrical harnesses for Electric Vehicles.

We will start by looking at the structure of electric vehicles and how many HV harnesses can be in an electric vehicle.

Next, I will show you what are the components of a HV harness and what are the basics for selecting them.

Here I will also discuss about HV harness design rules and best practices.

Then I also made a complete section about the main component of an EV – The traction battery.

Here I will show what are the components of a traction battery and the basics on how they work.

After all this theory we will design a few CAD projects where we implement everything we learned.

I design with Catia V5 but you can design this in any other CAD software as I provide step files.

With all of this said. This course is a cheat code.

To be able to take chance on opportunities you need experience, and experience is built only with practice.

Thanks for reading this and see you in the course.

Who this course is for:

Aspiring Harness Designers

Catia V5 - Electric Vehicle High Voltage Harness Design

What you'll learn

Explore related topics

Course content

Introduction4 lectures • 15min

EV high voltage harness design8 lectures • 1hr 27min

EV traction battery structure6 lectures • 27min

HV charger harness design7 lectures • 1hr 27min

Electric vehicle powertrain HV harness design12 lectures • 2hr 30min

Extra project - EV traction battery harness design17 lectures • 4hr 28min

Requirements

Description

Who this course is for: