Five major trends in electric vehicle wiring harness design

The rise of electric vehicles (EVs) is a major force for innovation in automotive wiring.

Electric and hybrid vehicles require complex wiring systems to manage high-voltage electric drivetrains, batteries, and advanced electronics. These systems require specialized wiring harnesses that can handle the increased voltages and complex electric propulsion connections.

The demand for these wiring harnesses is expected to increase significantly over the next decade. This growth is driven by several factors, including the adoption of advanced driver assistance systems, stricter government regulations, the expanding connected car ecosystem, and greater integration of communication devices in vehicles.

Here are five trends we’ve noticed in EV vehicle wiring harness design:

Advanced driver assistance systems (ADAS) and crash safety features require complex and robust wiring harnesses to manage high-speed data transmission and reliable power connections. The integration of vehicle-to-everything (V2X) communications also requires wiring harnesses that support reliable connectivity and data exchange.

Comfort features such as infotainment systems, climate control and electrically adjustable seats add complexity, requiring extensive and efficient wiring. To accommodate these features without adding weight to the vehicle, wiring harnesses are designed to be more compact and lightweight, using thinner wires, advanced materials and optimized routing strategies.

Ensuring durability and reliability is critical, driving the adoption of high-quality materials and advanced manufacturing methods. In addition, the flexibility of modular and scalable harness designs facilitates straightforward upgrades and customization to accommodate a wide range of vehicle models and trim levels. Together, these developments improve vehicle safety, comfort, and contribute to the continued advancement of automotive technology.

Optical fibers are becoming increasingly important in electric vehicle wiring, particularly due to their capabilities in high-speed data transmission and connectivity needs. Unlike traditional copper wires, optical fibers offer higher bandwidth and data transmission speeds, making them indispensable for handling large amounts of data quickly and reliably.

This capability is critical for powering advanced driver assistance systems (ADAS), infotainment setups, and vehicle-to-everything (V2X) communications, enabling real-time data processing critical to autonomous driving features and dynamic traffic updates. Fiber optics also demonstrate superior immunity to electromagnetic interference (EMI) and signal attenuation over long distances, ensuring consistent performance and data accuracy in varying automotive environments. Their integration supports seamless connectivity within ADAS networks, improving the accuracy of safety features such as collision avoidance and lane keeping assist.

Modular wiring systems are transforming EV wiring harness design by enabling increased flexibility and customization. These systems use prefabricated modules or wiring segments that can be easily interconnected or replaced to accommodate a variety of vehicle configurations and optional features. This adaptability simplifies the manufacturing process and speeds up the assembly line. Each module is rigorously tested and adheres to standardized specifications, ensuring consistent quality and reliability across different vehicle models and production runs. Modular design benefits maintenance, allowing individual modules to be replaced without extensive disassembly, making repairs easier. This, in turn, reduces downtime and repair costs.

In terms of cost benefits, while initial setup expenses may be higher due to module development, long-term savings can be achieved through simplified assembly procedures, improved inventory management, and streamlined after-sales service. Modular systems also enable automakers to quickly adopt new technologies, such as ADAS and connectivity solutions. This feature ensures that vehicles remain competitive and meet evolving regulatory standards. Ultimately, modular wiring systems play a vital role in improving production efficiency and enabling electric vehicles to effectively meet different consumer preferences and technological advancements.

Smart wiring harnesses with integrated sensors use real-time data collection and analysis to predict potential faults and problems in EV electrical systems. This proactive approach enables vehicle systems or maintenance personnel to detect early warning signs and take preventive measures, such as inspecting and repairing problem areas before they cause serious failures. As a result, this predictive maintenance strategy reduces downtime, improves vehicle reliability, and effectively reduces overall maintenance costs. Ultimately, these advances help improve vehicle safety and performance by proactively resolving potential problems before they affect vehicle operation.

The focus here is on minimizing the environmental impact of the entire wiring harness lifecycle. This means using environmentally friendly materials (such as recycled plastics) and lightweight options to reduce the vehicle's footprint. In addition, manufacturers are optimizing production to minimize waste and use renewable energy. Finally, designing wiring harnesses for easy disassembly allows for proper recycling and reduces landfill waste. These practices pave the way for a more environmentally friendly automotive industry.

EV wiring harnesses and other EV electrical systems are becoming a production bottleneck. For one thing, electric vehicles require nearly twice as much wiring as fossil fuel vehicles. Traditional manual production struggles to keep up with the sheer volume and complexity of EV wiring. Unlike standard wiring harnesses, EV versions manage separate high-voltage systems for the battery and motor, adding to the complexity. The growing scarcity of skilled labor further tightens the knot.

Automation becomes the hero, untangling this wiring maze. New approaches integrate electrical functionality directly into components, enabling lighter, more compact designs. Imagine 3D-printed parts with built-in wiring, eliminating waste and the need for oversized cables.

The benefits extend beyond efficiency. Automation opens up a completely digital design process. Imagine seamlessly integrating electrical functionality into any surface, curved or flat. This enables manufacturers to push the boundaries of EV design and expand this approach across every industry that relies on electrical functionality.

The success of electrification depends on the ability to produce these complex wire harnesses. Automation capable of handling the increased volume, lighter wire harnesses and complete design digitalization are key to unlocking the full potential of electrification and a cleaner future.

Smart wiring harness manufacturing has great potential to enhance the electric vehicle market through several key advancements:

By integrating sensors and data analytics into wire harness manufacturing, manufacturers can gather real-time insights into the production process. This allows for continuous monitoring of quality metrics, production efficiency, and predictive maintenance of equipment. For the electric vehicle market, this means improved reliability and quality assurance in wire harness production, thereby improving vehicle performance and durability.

IoT (Internet of Things) technology enables connectivity between machines, systems, and processes in a manufacturing environment. In an electric vehicle wiring harness manufacturing environment, IoT facilitates seamless communication and data exchange between assembly line components. This integration supports adaptive manufacturing processes where production systems can dynamically adjust to optimize efficiency, reduce downtime, and increase overall productivity.

Smart wiring harness manufacturing also helps achieve the sustainability goals of the electric vehicle industry. By optimizing energy use, minimizing material waste through advanced production technologies such as additive manufacturing and recycling programs, manufacturers can reduce the environmental impact of wiring harness production. Sustainable practices not only meet regulatory requirements, but also attract environmentally conscious consumers, thereby increasing the market appeal of electric vehicles.