Charging infrastructure combines high current, outdoor exposure and unattended operation. GB/T 18487.1 governs safety; here are the four things harnesses must get right.
1. Temperature rise: the hidden battlefield
Every joint heats at full power. Standards limit accessible surface temperature rise (on the order of +50K for metal). Oversize conductors, keep crimp resistance at milliohm level, protect busbar joints from oxidation. Thermal failures are the top warranty issue.
2. Current rating and margin
Size by maximum continuous output, derated for hot enclosures (60°C+ in sun-baked piles) and mutual heating in shared raceways.
3. EMC and signal integrity
Switching noise disturbs CP and communication loops. Shield power runs, twist and separate CP/CAN/PLC lines, and expect full EMC testing at system level.
4. Weathering and mechanical protection
Outdoor runs face UV, humidity and salt spray; gun cables endure hundreds of daily drag-cycles and need flexible, cold-crack-resistant jackets (-40°C) with strain relief at the head.