Introduction: The "neural network" of automobiles is undergoing a revolution

When we marvel at the speed, appearance or intelligent configuration of a car, we seldom notice that crucial element like blood vessels and nerves - the wiring harness. It transmits energy and information, maintaining the coordinated operation of all components of the car. However, with the development of automotive intelligence and electrification, traditional wiring harness production has become a bottleneck in the industry. This article will explore how new wiring technologies are transforming wire harness production and leading the industry towards an automated future.

Industry Status Quo and Challenges: The "Growing Pains" of Traditional Wiring Harnesses

The predicament of the production mode

Due to its softness and irregular shape, the production of wire harnesses is highly dependent on manual labor, which brings about many problems: labor costs account for 95% of the price of wire harnesses. The traditional method requires 6 to 10 people to produce over 2,500 wire harnesses, while an automated production line only needs 1 person. Manual operation is prone to errors and has a persistently high failure rate.

The complexity of wiring harness design

The increasing functions of automobiles have made wiring harnesses more complex. A regular family car has 20,000 to 30,000 components, which require wiring harnesses for connection and coordination. The three-dimensional space inside the vehicle forces the wiring harness to be laid out in a circuitous way. The wiring harness length of traditional models can reach 5,000 meters, which not only takes up space but also increases weight, affecting fuel efficiency and range.

Standard chaos and supply chain risks

Connectors are the "joints" of wire harnesses, but there are over 200 specifications in the industry, just like there are hundreds of models of common "screws", which are incompatible. This increases design complexity and also brings supply chain risks - the war in Ukraine in 2022 disrupted the European wiring harness supply chain, directly causing a decline in local car sales.

New challenges brought by new energy vehicles

New energy vehicles have higher requirements for high-voltage wiring harnesses, which need to possess characteristics such as high voltage, large current, and high protection. At the same time, they need to be lightweight to enhance the driving range. The design and manufacturing process of traditional wiring harnesses have been unable to meet the demands, and the industry urgently needs a technological revolution.

Revolutionary Technological Breakthrough: The "Four Major Innovations" in Wiring Technology

Innovation in electronic and electrical architecture: From Distributed to Centralized

In traditional distributed architectures, each electronic control unit (ECU) is independent and requires a large number of wiring harnesses for connection, resulting in large wiring harnesses and complex signal transmission. The centralized architecture integrates ECU functions and shortens the transmission path: the wiring harness length of Tesla Model 3 has been reduced to 1.5 kilometers, and that of Cybertruck has been shortened by 77% to less than 1 kilometer. The "Four-leaf Clover" architecture of Zero Run Auto keeps the total length of the wiring harness within 1.5 kilometers and weighs 23 kilograms, which is 15 kilograms lighter than the traditional architecture.

Modular design: The wisdom of simplifying complexity

Modular design divides functions into basic modules (mandatory functions, such as BCM, diagnosis, etc.) and functional modules (optional functions, such as ABS, headlamps, etc.), and produces wiring harnesses through the combination of these modules. Its advantages are significant: reducing the types of wiring harnesses, improving design efficiency, and enhancing the reliability of layout. A certain heavy-duty truck model divides the chassis wiring harness into 11 basic modules, increasing the design efficiency by 40% and reducing the types of wiring harnesses by 30%.

Automated production technology: A New Chapter in intelligent manufacturing

The automation of wire harness production has long been a pain point in the industry, but breakthroughs have been made in recent years. Kunshan Huguang has built an intelligent manufacturing system, using industrial robots, 5G and other technologies to achieve full-process automation. The intelligent wire warehouse can deliver 5,000 barrels of wires per day with zero errors. The production line has been reduced from 200 people to 20, and the production cycle of high-voltage wire harnesses is only 20 seconds. The Ethernet production line of Langfang Leni can operate 64 workstations with one device. One signal line comes off the production line in 4 seconds, and one person can replace the work of dozens of people.

New materials and new processes: The combination of lightweight and high performance

To meet the demands of new energy vehicles, new materials and processes have emerged: copper alloy conductors are reduced in weight by 10% to 20%, and aluminum alloys are widely used because their density is only one-third that of copper. Insulating materials such as polytetrafluoroethylene can withstand temperatures up to 150℃ and have stronger resistance to electromagnetic interference. Martin Technologies' eSPDM technology can save 90% of wiring materials. The coaxial power supply technology transmits power and data simultaneously through a single cable, simplifying the electrical architecture.

Future trend outlook: Intelligence, wireless and green

Intelligent wiring harnesses: From passive transmission to active perception

In the future, more sensors will be integrated into the wiring harness to collect real-time data such as temperature and current, enabling self-diagnosis and predictive maintenance. Byd's intelligent wiring harness monitoring system has initiated this trend and will provide precise information support for autonomous driving in the future.

Wireless connection: Reduce physical wiring harnesses

The application of technologies such as Bluetooth, Wi-Fi and 5G in scenarios like in-car entertainment and sensor data transmission can reduce the use of wiring harnesses. With the maturation of wireless charging technology, power supply harnesses are also expected to be significantly reduced, promoting the simplification of wiring.

Lightweight and green: Choices for sustainable development

The lightweighting of wire harnesses will be achieved through new lightweight materials and structural optimization. The use of eco-friendly materials and recyclable designs will reduce the environmental impact throughout the entire process of production, use and disposal, promoting the green development of the industry.

Standardization and platformization: The Key to cost reduction and efficiency improvement

In the future, the industry will unify the specifications of connectors and wire harnesses and reduce the number of models. Platform-based design enables flexible combinations of different vehicle models through modular platforms, reducing design and production costs and enhancing efficiency.

Conclusion: Wiring technology innovation leads the future of the automotive industry

Although wiring harnesses may seem unremarkable, their technological innovations have had a profound impact on the automotive industry. From manual production to smart factories, from distributed to centralized architectures, every breakthrough in wire harness technology has driven the industry towards high efficiency, intelligence and environmental protection. The cases of enterprises such as Tesla and Kunshan Huguang prove that technological innovation in wiring can reduce costs, improve efficiency and enhance quality. With the development of new energy and intelligent connected vehicles, wiring harness technology will have a greater space for innovation.