What are the key processes and acceptance standards for the construction of energy storage wiring harnesses?
18/05/2026

The construction of energy storage wiring harnesses is the core of the concealed electrical works for energy storage. The standardization of the construction process directly determines the operational stability and safety of the energy storage system for more than 10 years. Based on the group standard "Wiring Harnesses and Connectors for Electric Energy Storage Systems" and the State Grid's acceptance specifications for energy storage projects, the industry has formed a complete set of key construction processes and standardized acceptance systems, covering the entire process from wiring, crimping, connecting, protecting, to testing. All projects must meet the standards before the cabin can be sealed and delivered. Firstly, the key process of wiring construction follows the principles of independent routing, separation of strong and weak electricity, priority of heat dissipation, and prevention of abrasion and vibration. All power wiring harnesses, signal wiring harnesses, and communication wiring harnesses are laid in independent trays and wireways, with no mixed pipes or trays allowed. The parallel spacing between strong and weak electricity is ≥30cm, and they are arranged at a 90-degree angle for vertical crossing, with added shielding and isolation. The wiring harnesses are arranged neatly and orderly in layers, without tight stacking, twisting, or sharp bends. The wire tubes and trays have no sharp edges to avoid abrasion of the wiring harness insulation. All wiring harnesses are kept away from high-temperature heat sources such as battery cells, PCS, and inverters, with sufficient heat dissipation gaps reserved. For equipment vibration points, expansion allowance is reserved for the wiring harnesses to avoid vibration, pulling, and wire breakage. Wiring inside the cabin avoids low-lying water-accumulating areas, with proper waterproof slope design to prevent moisture accumulation. Secondly, the terminal crimping and connecting process strictly follows standardized crimping and fastening procedures. Specialized terminals for energy storage with matching specifications are used, ensuring that the wire cores are fully inserted into the slots without loose wires, missed crimps, or protrusions. Special hydraulic crimping tools are used for double-layer crimping, and a tensile test is conducted after crimping to ensure firmness and reliability. The connecting end faces are thoroughly cleaned and deoxidized, with conductive paste evenly applied. Torque wrenches are used to tighten bolts to the standard torque, with anti-loose washers and spring washers added, and anti-loose marks made. All connectors are free of loose connections, gaps, and sparking hazards. Thirdly, the insulation and protection process ensures that the outer skin of the wiring harness is free of damage, scratches, and extrusion deformation, with the insulation layer intact and intact. Terminal connectors and exposed conductors are all equipped with flame-retardant insulation sheaths and sealing sleeves for waterproof, dustproof, corrosion-resistant, and short-circuit protection. Protective rings are added at the locations where the wiring harnesses pass through walls and boards to prevent wear. The wiring harnesses in areas where electrolyte leakage is prone are thickened for protection and enhanced corrosion resistance; The shielding layer of the shielded wire harness is reliably grounded at one end, with grounding resistance meeting standards, and there are no issues such as suspension or multi-point grounding interference. Finally, the core standards for completion acceptance are divided into three major modules: appearance acceptance, process acceptance, and performance acceptance. Appearance acceptance requires neat wiring harness arrangement, clear identification, intact sheath, no oxidation or blackening, and no damage or contamination; process acceptance requires strong and weak electricity separation to meet standards, sufficient heat dissipation, terminal fastening and anti-loosening, complete protection, and standardized grounding; performance acceptance is the core hard indicator, with insulation resistance at room temperature ≥100MΩ, no breakdown or leakage in high-voltage withstand voltage test, normal line continuity, voltage drop meeting standards, no abnormal temperature rise, stable communication signal without interference distortion, no high-temperature anomalies in infrared temperature measurement at all points, and smooth system charging and discharging operation without fault alarms. All process and performance indicators must meet standards before the energy storage wire harness project can be accepted, ensuring long-term safe and stable operation of the system.

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