GB/T 37133-2025 High voltage connection system for electric vehicle
1 Scope
This document specifies the requirements, test methods and inspection rules for high voltage connection systems of electric vehicles.
This document is applicable to the connection system of electric vehicles with the circuit voltage of Class B specified in GB18384-2020. This document may serve as a reference for the part of electric circuits conducting Class A voltage in the connection system.
This document is not applicable to conductive charging connections of electric vehicles.
This document is not applicable to battery swap interface.
2 Normative references
The following documents contain provisions which, through reference in this text, constitute provisions of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies.
GB/T 2423.8 Environmental testing for electric and electronic products - Part 2: Test methods - Test Ed: Free fall
GB/T 2423.17 Environmental testing for electric and electronic products - Part 2: Test methods - Test Ka: Salt mist
GB/T 3956 Conductors of insulated cables
GB/T 5095.2 Electromechanical components for electronic equipment - Basic testing procedures and measuring methods - Part 2: General examination, electrical continuity and contact resistance tests, insulation tests and voltage stress tests
GB/T 5095.3 Electromechanical components for electronic equipment - Basic testing procedures and measuring methods - Part 3: Current-carrying capacity tests
GB/T 5095.5 Electromechanical components for electronic equipment - Basic testing procedures and measuring methods - Part 5: Impact tests (free components), static load test (fixed components), endurance tests and overload tests
GB/T 5095.9-1997 Electromechanical components for electronic equipment - Basic testing procedures and measuring methods - Part 9: Miscellaneous tests
GB/T 5169.11-2017 Fire hazard testing for electric and electronic products - Part 11: Glowing/hot-wire based test methods - Glow-wire flammability test method for end-products (GWEPT)
GB/T 5585.1 Copper or aluminium and its alloy bus bars for electrical purposes - Part 1: Copper and copper alloy bus bars
GB/T 5585.2 Copper or aluminium and its alloy bus bars for electrical purposes - Part 2: Aluminium and copper alloy bus bars
GB/T 7762-2014 Rubber, vulcanized or thermoplastic - Resistance to ozone cracking - Static strain test
GB/T 11918.1-2014 Plugs, socket-outlet and couplers for industrial purposes - Part 1: General requirements
GB/T 16422.2 Plastics - Methods of exposure to laboratory light sources - Part 2: Xenon-arc sources
GB/T 16935.1-2023 Insulation coordination for equipment within low-voltage supply systems - Part 1: Principles, requirements and tests
GB 18384-2020 Electric vehicles safety requirements
GB/T 19596 Terminology of electric vehicles
GB/T 25085.2-2024 Road vehicles - Automotive cables - Part 2: Test methods
GB/T 28046.3-2011 Road vehicles - Environmental conditions and testing for electrical and electronic equipment - Part 3: Mechanical loads
GB/T 28046.4-2011 Road vehicles - Environmental conditions and testing for electrical and electronic equipment - Part 4: Climatic loads
GB/T 28046.5-2013 Road vehicles - Environmental conditions and testing for electrical and electronic equipment - Part 5: Chemical loads
GB/T 30038 Road vehicles - Degrees of protection (IP-Code)
GB/T 30512-2014 Requirements for prohibited substances on automobiles
GB/T 43332-2023 Safety requirements of conductive charging and discharging for electric vehicles
ISO 16750-4:2023 Road vehicles - Environmental conditions and testing for electrical and electronic equipment - Part 4: Climatic loads
3 Terms and definitions
For the purpose of this document, the terms and definitions given in GB 18384-2020, GB/T 19596 and GB/T 43332-2023, as well as the following apply.
3.1
high voltage connector
components with one or more groups of conductor terminals and insulating sheaths for electric connection/separation between high voltage cables and between high voltage cables and high voltage components of electric vehicles
3.2
high voltage connection system
connecting device composed of high voltage cable, high voltage connector and/or other conductor components for conducting Class B voltage between high voltage components of electric vehicle
Note: the high voltage connection system may also include auxiliary components such as bellows, heat-shrinkable tubes, fixing devices and protective tubes (grooves).
3.3
flexible copper busbar
conductor cable made of flexible copper busbar
4 General requirements
4.1 Appearance
4.1.1 The appearance of the high voltage connection system shall be clearly and firmly marked with the basic product information.
4.1.2 The marks of the high voltage connection system shall meet the requirements of 5.1.2 of GB 18384-2020.
4.1.3 The accessible surfaces of the high voltage connection system shall be free from burrs, flash and similar sharp edges.
4.1.4 The high voltage connection system shall be free from defects such as damage and deformation.
4.2 Structure
4.2.1 When the high voltage connection system is normally connected, its protection grade shall meet the requirements for IPXXD. If the high voltage connection system can be manually disconnected without the tool, the protection grade of each parts of the non-connected high voltage connection system shall meet the requirements for IPXXB.
4.2.2 For a high voltage connection system with high voltage interlocking function, the power and signal/control contacts of the system shall meet the following requirements:
——when the high voltage connection system is connected, the power contacts are connected first, and the signal/control contacts are connected later;
——when the high voltage connection system is disconnected, the signal/control contacts are disconnected first, and the power contacts are disconnected later;
——the difference between the contact length of the power contact and the high voltage interlock contact is more than 1mm.
4.2.3 The positions of the high voltage connection system for cable crimping, threaded connecting and welding shall be free from looseness, breakage and other connection defects.
4.2.4 If the high voltage connection system has a shielding layer, the connection system shall be equipped with a grounded structure.
4.2.5 After the connectors of the high voltage connection system are fully connected, the effective contact length of the contacts shall not be less than 1mm.
4.2.6 When the matched connectors of the high voltage connection system are connected, the phenomena such as contact damage, unexpected conduction between different contacts caused by metal shells or foreign bodies, structural damage of sealing ring and other accessories, as well as any displacement or deformation affecting the function or performance shall not be found.
Contents
1 Scope
2 Normative references
3 Terms and definitions
4 General requirements
5 Technical requirements
6 Test methods
7 Inspection rules
Annex A (Normative) Requirements for high voltage connector
Annex B (Normative) Requirements for high voltage cable
Annex C (Informative) Requirements for flexible copper busbar in high voltage connection system
Annex D (Informative) Installation dimension of fixed end of typical connector
Annex E (Informative) Interface structure dimension of fixed end of typical connector
Annex F (Informative) Method for measuring the shielding effectiveness of cable of high voltage connection system
Bibliography
