新能源汽车高速以太网线束国产化技术分析

    Discussion on New Energy Vehicle High-Speed Ethernet Wiring Harness Localization

    • 摘要: 基于单对以太网(one-pair Ethernet,OPEN)联盟TC9技术委员会制定的《1000BASE-T1链路段A类(STP)信道及组件要求》,研究新能源汽车用高速以太网线束的国产化关键技术,重点分析传输性能与电磁兼容性能测试方法,包括特性阻抗、插入损耗、回波损耗等参数,以及三同轴管中管法评估屏蔽性能。对比国产线束与进口线束的性能参数发现,国产线束在基础传输性能(如特性阻抗、传播延迟、插入损耗)上已接近国际水平,但在高频信号完整性和抗干扰能力方面仍存在差距。具体表现为:纵向转换损耗和纵向转换传输损耗裕度较低,抗共模干扰能力不足;外部串音衰减性能较弱,多线束干扰抑制能力待提升;耦合衰减和屏蔽衰减在高频段(30~600 MHz)未达标,尤其在500 MHz以上频段与进口产品差距显著。进一步分析表明,这些差距主要源于屏蔽结构工艺不足,如编织角度偏大、铝塑带绕包方式及连接器压接精度等因素。为实现国产化突破,需要在以下方面加强研发:①优化高频屏蔽工艺,采用小角度编织和纵包铝塑带结构;②提升连接器与线缆的精密装配技术,减少信号泄漏。

       

      Abstract: Based on Channel and Components Requirements for 1000BASE-T1 Link Segment Type A (STP) formulated by TC9 Technical Committee of one-pair Ethernet (OPEN) Alliance, key technologies for domestic production of high-speed Ethernet harnesses for new energy vehicles were studied, and test methods for transmission performance and electromagnetic compatibility, including parameter tests such as characteristic impedance, insertion loss, and return loss, as well as shielding performance evaluation by three-axis tube method were emphasized. Comparing performance data of domestic and imported harnesses, it was found that domestic harnesses had approached international standards in basic transmission performance (such as characteristic impedance, propagation delay, and insertion loss), but there was still a gap in terms of high-frequency signal integrity and anti-interference capabilities. Specifically, margins of longitudinal conversion loss and longitudinal conversion transfer loss were low, and anti-common-mode interference capability was insufficient; external crosstalk attenuation performance was weak, and multi-bundle interference suppression capability needed to be improved; coupling attenuation and shielding attenuation were not up to the standards in high-frequency band (30~600 MHz), especially above 500 MHz there was significant gap with imported products. Further analysis indicated that these gaps mainly resulted from insufficient shielding structure processing, such as large weaving angles, aluminum-plastic tape winding methods, and connector pressing accuracy. To achieve breakthroughs in domestic production, research efforts should be strengthened in the following aspects: firstly, optimize high-frequency shielding processes by adopting small-angle weaving and longitudinal aluminum-plastic tape structures; secondly, improve precision assembly technology of connectors and cables to reduce signal leakage.

       

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