Abstract:

It is increasingly important to study the collision safety of the battery system with the development and popularization of new energy vehicles. As a key part of the high voltage electrical system of new energy vehicle， it is particularly important to study its electrical safety performance under crash condition of the high voltage harness. Based on the typical extrusion load that the HV-cable of the battery system may suffer under the crash conditions， the harness with a diameter of 15.8 mm is selected to design the dynamic and static compression tests under two working conditions of the D5 cylindrical surface and V60 wedge surface. During the test， real-time monitoring of short circuit between the punch and the internal conductor of the harness is conducted， and the tensile and compression tests are carried out on the three component materials of sheath， insulation layer and conductor to calibrate the corresponding material model. Through the harness structure test and component material test， the one component homogenization model of HV-cable and the two-component model of conductor-equivalent insulation layer are calibrated respectively. The results show that there is a strong dynamic effect of HV-cable under mechanical load， and the dynamic mechanical response increases. The short circuit behavior of HV-cable is highly related to the external loading condition and loading speed. The simulation results of the two HV-cable simulation models using element deletion to predict the cable short circuit are basically consistent with the test results， and the two models can accurately predict the short circuit risk under extrusion condition.

Key words: new energy vehicle, HV-Cable, dynamic and static extrusion, component material test, homogenization model, two components model