New Energy Power parts Electrical protection box assembly 3791010-KT6A0

As the "safety barrier" of the NEV’s high-voltage system, the 3791010-KT6A0 assembly delivers comprehensive, real-time protection against electrical hazards to safeguard the vehicle, passengers, and maintenance personnel. It executes four key safety functions: 1) Overcurrent Protection: Integrated high-voltage fuses (rated for 100A-500A) quickly interrupt excessive current caused by short circuits (e.g., cable damage), preventing component burnout or fire; 2) High-Voltage Isolation: The box’s insulated housing and internal partitions provide ≥2500V AC insulation resistance (per IEC 60664), isolating high-voltage circuits from the vehicle’s low-voltage systems and chassis; 3) HVIL Monitoring: Built-in HVIL circuits detect unauthorized opening of the box (e.g., during maintenance) and send signals to the VCU to disconnect the high-voltage battery within 100ms; 4) Pre-Charge Protection: A pre-charge resistor limits inrush current when the high-voltage system is activated, preventing damage to capacitors in the motor inverter. These protections collectively comply with global NEV safety standards (e.g., ISO 6469), minimizing electrical accident risks

The 3791010-KT6A0 electrical protection box features a rugged, NEV-optimized structure built to withstand the unique challenges of high-voltage systems and under-vehicle conditions—including extreme temperatures, moisture, dust, and vibration. The outer housing is constructed from glass-fiber reinforced polyamide (PA66+GF30) with a flame-retardant rating (UL94 V-0), providing resistance to high temperatures (operating range: -40°C to 125°C) and preventing flame spread in case of internal electrical faults. The internal terminal blocks and busbars are made of high-conductivity copper (T2 grade) with tin plating, ensuring low electrical resistance (≤5mΩ) and corrosion resistance. The box’s sealing system uses ethylene propylene diene monomer (EPDM) gaskets with IP6K9K waterproof/dustproof rating, protecting internal components from rain, road salt, and dust intrusion. Additionally, the housing is reinforced with anti-vibration mounts, absorbing up to 20G peak acceleration (per ISO 16750-3) to prevent component loosening during rough road operation

The 3791010-KT6A0 is calibrated with NEV-specific technical parameters to ensure optimal safety and performance in high-voltage systems. Its maximum rated voltage is 1000V DC (compatible with 800V NEV platforms), with a continuous current handling capacity of 300A-600A (matching the power output of 150kW-300kW drive motors). The integrated fuses have a breaking capacity of 10kA-50kA, sufficient to interrupt large short-circuit currents in high-voltage batteries. The HVIL circuit operates on the NEV’s 12V low-voltage system, with a response time of ≤50ms to ensure rapid high-voltage disconnection. The box’s internal temperature sensor monitors ambient temperature and sends data to the VCU, triggering cooling measures (e.g., fan activation) if temperatures exceed 100°C. Additionally, the terminal blocks support cable cross-sections of 25mm²-150mm², accommodating the high-current cables used in NEV powertrains

The 3791010-KT6A0 electrical protection box assembly meets strict global NEV high-voltage safety standards to ensure reliability in critical safety applications. It is manufactured in accordance with ISO/TS 16949 (automotive quality management system) and complies with key NEV safety standards: IEC 60664 (insulation coordination for high-voltage systems), ISO 6469-3 (safety requirements for EV electrical systems), and GB/T 18384.3 (Chinese EV safety standards). Each unit undergoes 100% factory testing, including: 1) Electrical safety testing (insulation resistance, dielectric strength, HVIL function verification); 2) Environmental testing (temperature cycling, humidity, vibration, salt spray corrosion); 3) Durability testing (10,000+ opening/closing cycles of HV connectors, 15-year lifespan simulation); 4) Flame resistance testing (UL94 V-0 verification). To support NEV manufacturers and repair facilities, the assembly comes with a 36-month/100,000km warranty and dedicated technical support—including HVIL circuit troubleshooting, high-voltage safety training, and installation guidance for compliance with maintenance safety protocols