Abstract: In the fire accidents of new energy vehicles after collisions, short circuit of high-voltage components is one of the important inducements, and relevant research is relatively insufficient compared with fire caused by battery pack damage. To improve the safety performance of new energy vehicles, this paper focuses on the fire problem caused by short circuit of high-voltage components. Taking the integrated power system as the research object, a design process and method for highvoltage components covering layout design, structure analysis and test verification is constructed. Through designing subsystem tests and establishing safety performance evaluation indicators, the causes of fire in high-voltage components are systematically analyzed and corresponding prevention and control countermeasures are proposed. Research results indicate that based on the constructed forward development and design process, the maximum collision load that the integrated power system of a specific vehicle model can withstand is determined to be 72.4 kN through simulation. Considering the safety factor, the crash worthiness index is set to 90 kN. Verified by subsystem tests and vehicle collision tests, the system shows no structural damage or functional failure after collision, meeting the electrical safety technical requirements. This process can provide technical support for the design of high-voltage components in vehicles, effectively improve the safety in real traffic accidents, and reduce the risk of short-circuit and fire.

Key words: collision-induced fire; test design; evaluation indicator; subsystem verification

摘要： 新能源汽车碰撞后起火事故中，高压部件短路是重要诱因之一，相关研究中针对电池 包破损起火的研究较多，而针对高压部件短路的研究相对薄弱。文章以提升新能源汽车碰撞 安全性为目的，聚焦高压部件短路起火问题，以集成电源系统为研究对象，构建了一套涵盖 前期布置设计、受力分析及试验验证的高压部件设计流程与方法。通过设计子系统试验，建 立安全性能评价指标，系统分析高压部件起火原因并提出防控对策。研究结果表明，基于所 构建的正向开发设计流程，通过仿真分析确定某车型集成电源系统在碰撞场景下的最大承受 载荷为 72.4 kN，考虑安全系数后将耐撞性指标设定为 90 kN，经子系统及实车验证，该系统 在碰撞后未出现高压部件结构破损、功能失效等现象，满足整车碰撞后电安全技术要求。该 正向开发设计流程可为新能源汽车高压部件的安全设计提供技术支撑，有效提升车辆在真实 交通碰撞事故中的安全性，降低短路起火风险。

关键词: 碰撞起火；试验设计；评价指标；子系统验证