GB/T 37133-2025 PDF English
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High voltage connection system for electric vehicle
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| GB/T 37133-2018 | English | 145 |
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Technical Specifications of High Duty Cables and Connectors for Electric Vehicles
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GB/T 37133-2025: High voltage connection system for electric vehicle---This is an excerpt. Full copy of true-PDF in English version (including equations, symbols, images, flow-chart, tables, and figures etc.), auto-downloaded/delivered in 9 seconds, can be purchased online: https://www.ChineseStandard.net/PDF.aspx/GBT37133-2025
GB
NATIONAL STANDARD OF THE
PEOPLE’S REPUBLIC OF CHINA
ICS 43.120
CCS T 35
Replacing GB/T 37133-2018
High voltage connection system for electric vehicle
Issued on. FEBRUARY 28, 2025
Implemented on. FEBRUARY 28, 2025
Issued by. State Administration for Market Regulation;
National Standardization Administration.
Table of Contents
Foreword... 5
1 Scope... 7
2 Normative references... 7
3 Terms and definitions... 9
4 General requirements... 9
5 Technical requirements... 12
6 Test methods... 17
7 Inspection rules... 23
Appendix A (Normative) Requirements for high-voltage connectors... 25
Appendix B (Normative) Requirements for high-voltage cables... 31
Appendix C (Informative) Requirements for soft copper busbars in high-voltage
connection systems... 33
Appendix D (Informative) Installation dimensions of typical connector fixed end... 35
Appendix E (Informative) Structural dimensions of interface of typical connector fixed
end... 43
Appendix F (Informative) Method for measuring electromagnetic shielding
effectiveness of high-voltage connection system... 47
References... 56
1 Scope
This document specifies the requirements, test methods, inspection rules for high-
voltage connection systems for electric vehicles.
This document applies to connection systems for electric vehicles that meet the B-level
voltage circuit specified in GB 18384-2020.The part in the connection system to
conduct A-level voltage circuit makes reference to this document.
This document does not apply to the conductive charging connection device of electric
vehicles.
This document does not apply to the battery swap interface.
2 Normative references
The contents of the following documents constitute the essential terms of this document
through normative references in the text. Among them, for the referenced documents
with dates, only the versions corresponding to the dates are applicable to this document;
for the referenced documents without dates, the latest versions (including all
amendments) are applicable to this document.
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 - 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 tests (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)
3 Terms and definitions
The terms and definitions as defined in GB 18384-2020, GB/T 19596, GB/T 43332-
2023, as well as the following terms and definitions, apply to this document.
3.1 High voltage connector
A component consisting of one or more sets of conductor terminals and insulating
sheaths, that provide electrical connection and separation functions between high
voltage cables of electric vehicles and between high voltage cables and high voltage
components.
3.2 High voltage connection system
A connection device composed of high voltage cables, high voltage connectors
and/or other conductor components that conducts Class B voltage between high
voltage components of electric vehicles.
3.3 Flexible copper busbar
A conductor busbar 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 basic product information.
4.1.2 The marking of the high-voltage connection system shall comply with the
provisions of 5.1.2 of GB 18384-2020.
4.1.3 The easily accessible surfaces of the high-voltage connection system shall be free
of burrs, flash, similar sharp edges.
4.1.4 The high-voltage connection system shall be free of defects such as damage and
deformation.
4.2 Structure
4.2.1 When normally connected, the protection level of the high-voltage connection
system shall meet IPXXD. If the high-voltage connection system can be manually
disconnected without tools, the protection level of each part of the high-voltage
connection system in the non-connected state shall meet IPXXB.
4.2.2 For high-voltage connection systems with high-voltage interlocking function, the
power and signal/control contacts of the system shall meet the following requirements.
4.2.3 There shall be no connection defects such as loosening and breaking in the cable
crimping, threaded connection, welding and other connection positions of the high-
voltage connection system.
4.2.4 If the high-voltage connection system has a shielding layer, the connection system
shall have a groundable structure.
4.2.5 After the connectors of the high-voltage connection system are fully connected,
4.3 Working environment
4.3.1 The temperature of the working environment of the high-voltage connection
4.4 Components in the system
In the high-voltage connection system, the requirements of the high-voltage connector
part shall meet Appendix A; the requirements of the high-voltage cable part shall meet
Appendix B; the requirements of the soft copper busbar can refer to Appendix C. The
installation dimensions of the typical connector fixed end can refer to Appendix D; the
typical connector interface structure dimensions can refer to Appendix E.
4.5 Materials and plating
4.6 Protection matching
5 Technical requirements
5.1 Withstand voltage
The insulation resistance between the conductors of different circuits of the high-
voltage connection system, between the conductors and the shell, between the
conductors and the shielding layer, between the shielding layer and the shell shall be
able to withstand the specified voltage without dielectric breakdown or arcing. Unless
otherwise specified, the leakage current during the test shall meet the requirements of
5.2 Insulation resistance
The insulation resistance between the conductors of different circuits of the high-
voltage connection system, between the conductors and the shell, between the
conductors and the shielding layer, between the shielding layer and the shell shall not
be less than 100 MΩ.
5.3 Insulation coordination
The insulation coordination of the high-voltage connection system shall comply with
the requirements of Table 3.
5.4 Current carrying capacity
The current carrying capacity of the current-carrying components in the high-voltage
connection system shall be tested; the current carrying capacity curve can be used as a
reference for product selection.
5.5 Temperature rise
Unless otherwise specified, the temperature rise of each point of the high-voltage
connection system shall not be greater than 55 K, when the high-voltage connection
system is in normal connection operation.
5.6 Short-term low-current overload
The current carrying capacity of the high-voltage connection system shall be able to
withstand a test of 2 times the rated current for 30 seconds. After the test, the high-
voltage connection system shall meet the requirements of 5.1, 5.2, 5.5.
5.7 Instantaneous high-current overload
The high-voltage connection system shall be able to withstand a shock test at 10-times
rated current for 1 s. After the test, the high-voltage connection system shall meet the
requirements of 5.1, 5.2, 5.5.
5.8 Protection level
After the high-voltage connection system is connected, the protection level of each
connection part of the system shall meet the requirements of Table 4.
5.9 Low-temperature storage
The high-voltage connection system shall be tested for low-temperature storage
according to the lower temperature limit specified in 4.3.1.After the test, the high-
voltage connection system shall meet the requirements of 5.1, 5.2, 5.8.
5.10 High-temperature storage
The high-voltage connection system shall be tested for high-temperature storage
according to the upper temperature limit specified in 4.3.1.After the test, the high-
voltage connection system shall meet the requirements of 5.1, 5.2, 5.8.
5.11 Salt spray resistance
Unless otherwise specified, the high-voltage connection system shall be subjected to a
salt spray resistance test with a test period of 96 h. After the test, the high-voltage
connection system shall meet the requirements of 5.1, 5.2, 5.8.
5.12 Chemical reagent resistance
The high-voltage connection system shall be subjected to a chemical reagent resistance
test. After the test, the high-voltage connection system shall meet the requirements of
5.1, 5.2, 5.8.
5.13 Vibration
The high-voltage connection system shall be subjected to a random vibration test; the
severity limit of random vibration and the test duration shall comply with the provisions
of ISO 16750-3.2023.During the test, the circuit continuity of the high-voltage
connection system shall be monitored; there shall be no momentary interruption with a
duration greater than 1 μs and a resistance greater than 7 Ω.
5.14 High-temperature durability
The high-voltage connection system shall be subjected to high-temperature durability
test; the test method shall be in accordance with the provisions of 6.16.After the test,
the high-voltage connection system shall meet the requirements of 5.1, 5.2, 5.5, 5.8.
The insulation resistance of the product shall be tested under high temperature
conditions; the insulation resistance shall not be less than 10 MΩ.
5.18 Ice water shock
The high-voltage connection system shall be subjected to ice water shock test in
accordance with 6.20.After the test, the high-voltage connection system shall meet the
requirements of 5.1, 5.2, 5.8.
5.19 Mixed gas corrosion
The high-voltage connection system shall be subjected to mixed gas corrosion test in
accordance with 6.21.After the test, the high-voltage connection system shall meet the
requirements of 5.1, 5.2, 5.8.
5.20 Mechanical shock
The high-voltage connection system shall be subjected to mechanical shock test in
accordance with 6.22.The mechanical shock test shall comply with the provisions of
4.2 of GB/T 28046.3-2011.During the test, there shall be no interruption with a duration
greater than 1 μs and a resistance greater than 7 Ω. After the test, the high-voltage
connection system shall meet the requirements of 5.1, 5.2, 5.5, 5.8.
5.27 Electromagnetic shielding effectiveness
For high-voltage connection systems with electromagnetic shielding characteristics, the
requirements of shielding effectiveness, transfer impedance, shielding attenuation, etc.
shall be negotiated by the supplier and the buyer.
6 Test methods
6.1 General test conditions
6.1.1 Unless otherwise specified, all tests shall be conducted under the following
environmental conditions.
6.1.2 The accuracy of all test instruments and equipment shall be at least one order of
magnitude higher than the accuracy of the measured index or the error shall be less than
one-third of the allowable error of the measured parameter.
6.2 Appearance and structure
Inspect the appearance and structure of the high-voltage connection system, to confirm
that the contact sequence of the contact pieces meets 4.2.3.
6.3 Withstand voltage
The following AC test voltage with a frequency of 50 Hz ~ 60 Hz shall be applied for 1min.
6.4 Insulation resistance
In different circuits of the high-voltage connection system, the insulation resistance is
measured in sequence between the high-voltage conductors and the high-voltage
conductors, between the high-voltage conductors and the interlocking conductors,
between the high-voltage conductors and the shell, between the high-voltage
conductors and the shielding layer.
6.6 Current carrying capacity
The current carrying capacity of the power contact and shielding layer of the connector
shall be measured according to test method 5b in GB/T 5095.3.
6.13 Salt spray resistance
The salt spray resistance test method shall be in accordance with GB/T 2423.17.
6.14 Chemical resistance
The chemical resistance test method shall be in accordance with GB/T 28046.5-2013.
6.15 Vibration
Unless otherwise specified, the vibration conditions shall be in accordance with ISO
16750-3.2023.During the test, the rated current shall be passed through the contacts of
the high voltage connection system and the temperature rise value shall be recorded. At
the same time, the instantaneous interruption test shall be carried out.
6.16 High temperature durability
The high-voltage connection system shall be placed under the highest temperature
conditions for 1008 h. The highest temperature conditions refer to the highest
temperature resistance level of the high-voltage connection system products. The
insulation resistance measurement under high temperature conditions is carried out in
the last 2 h of the test. Unless otherwise specified, the cables are arranged according to
the bending radius value not greater than 5 times the outer diameter of the wire.
6.20 Ice water shock
The ice water shock test method shall be in accordance with 5.4.3 of GB/T 28046.4- 2011.
6.21 Mixed gas corrosion
The mixed gas corrosion test method shall be in accordance with 5.8 of GB/T 28046.4- 2011.
6.22 Mechanical shock
The mechanical shock test method shall be in accordance with 4.2 of GB/T 28046.3- 2011.
6.23 Ozone resistance (when applicable)
The ozone resistance test method is in accordance with 9.2 of GB/T 7762-2014; the
following rules are adopted. the rubber parts in the high-voltage connection system are
placed in the test equipment; the test temperature is 40 °C ± 2 °C; the relative humidity
is 65%; the air flow rate is 12 mm/s ~ 16 mm/s; the exposure time is 72 h.
6.24 Drop (when applicable)
The drop test method is in accordance with GB/T 2423.8; the drop height is 1 m; the
single direction drops once; the number of drops is 6 in total.
6.25 Low pressure
Place the high-voltage connection system in a low-pressure box; set the low pressure
value according to Table A.2 of GB/T 16935.1-2023; the duration is 30 min. Perform
the voltage resistance test under low pressure conditions.
6.26 UV resistance
The UV resistance test is carried out according to method A in GB/T 16422.2, using
cycle 1, a total of 500 test cycles; the bending strength and impact strength of the
material are tested after the test.
7 Inspection rules
7.1 Inspection classification
Product inspection is divided into exit-factory inspection and type inspection.
7.2 Exit-factory inspection
7.2.1 High-voltage connection systems shall undergo exit-factory inspection.
7.2.2 All exit-factory inspection items of high-voltage connection system products shall
be qualified. See Table 5 for exit-factory inspection items.
7.3 Type inspection
7.3.1 See Table 5 for the inspection items and inspection sequence of type inspection
of high-voltage connection systems. The number of samples in each group is 3.
7.3.2 All type inspection items of high-voltage connection system samples shall be
qualified.
......
Source: Above contents are excerpted from the full-copy PDF -- translated/reviewed by: www.ChineseStandard.net / Wayne Zheng et al.
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