New Energy Power parts High voltage control system bracket assembly 2833040-TE880

The bracket features a safety-centric design that complies with international NEV high voltage safety standards (e.g., IEC 61557, GB/T 18384). Key safety-focused elements include:

Insulation Integration: The bracket’s mounting surfaces for high voltage components are lined with a 2-3mm thick flame-retardant polyamide (PA66+GF30) insulation pad, ensuring electrical isolation between the metal bracket and high voltage parts (achieving a minimum creepage distance of 12mm and clearance of 8mm, as required for 600V+ systems).

Shock Absorption: Four rubber damping feet (made of EPDM with 50±5 Shore A hardness) are installed at the bracket’s chassis mounting points. These feet absorb vibration from the vehicle’s operation, preventing mechanical stress on high voltage components and reducing the risk of wire harness loosening.

Heat Dissipation Channels: The bracket’s side panels feature 5×15mm rectangular vents and a grid-like bottom structure, facilitating airflow around the high voltage control unit. This design helps dissipate heat generated during component operation (up to 80W), preventing overheating and ensuring stable performance

Bracket Frame: Constructed from 1.5-2mm thick cold-rolled high-strength steel (HSS) with a tensile strength of ≥ 590 MPa. The steel undergoes a galvannealed coating process (50-80g/m² zinc layer) to provide corrosion resistance (passing 1000+ hours of neutral salt spray testing per ISO 9227), critical for under-chassis or battery pack-mounted applications.

Insulation Components: As mentioned, insulation pads and damping feet use flame-retardant materials (UL94 V-0 rating) that resist combustion and prevent the spread of fire in extreme conditions.

Reinforcement Ribs: The bracket’s top and bottom surfaces are reinforced with 3mm thick triangular ribs, which increase torsional rigidity by 40% compared to non-reinforced designs. This prevents bracket deformation under heavy loads (up to 50kg, including the weight of the high voltage control unit) or during vehicle collisions

This bracket assembly fulfills three critical functions in NEV high voltage systems:

Component Securement: It provides a stable, vibration-resistant mounting platform for high voltage control units, ensuring these components remain fixed even during rough-road driving or sudden acceleration/deceleration. This prevents damage to sensitive electrical connections (e.g., high voltage terminals) and maintains system functionality.

Safety Isolation: By integrating insulation and grounding features (the bracket includes a dedicated grounding bolt for static discharge), it reduces the risk of electrical leakage or short circuits—protecting both the vehicle’s electrical system and passengers from high voltage hazards.

System Compatibility: The bracket’s design accommodates NEV wire harness routing, with pre-drilled 10mm diameter holes for cable ties. This keeps high voltage wire harnesses organized and separated from low-voltage lines, complying with NEV electromagnetic compatibility (EMC) standards (e.g., CISPR 25) and reducing signal interference.

This high voltage control system bracket assembly meets global NEV safety and quality standards, including GB/T 31467 (Safety requirements for electric vehicle power batteries), IEC 60664 (Insulation coordination for equipment within low-voltage systems), and IATF 16949 (automotive quality management). Each unit undergoes comprehensive pre-shipment testing:

Structural Load Testing: Subjecting the bracket to 1.5× the maximum rated load (75kg) for 24 hours to ensure no permanent deformation or weld failure.

Electrical Insulation Testing: Measuring insulation resistance between the bracket frame and insulation pad (≥ 100 MΩ at 1000V DC) to confirm high voltage isolation.

Vibration Durability Testing: Exposing the bracket to 500 hours of sinusoidal vibration (5-2000 Hz, 15 g acceleration) to simulate NEV operation—no component loosening or structural damage is allowed.

Environmental Testing: Conducting temperature cycling (-40°C to 85°C, 200 cycles) and humidity testing (95% RH at 40°C, 500 hours) to validate performance in extreme climates.

Backed by a 24-month manufacturer’s warranty, the assembly ensures reliable, long-term protection for NEV high voltage control systems in both passenger and commercial new energy vehicles