Automotive wiring harness upgraded to "triple"

"The breakthrough growth of new energy vehicles has gradually transformed the domestic automotive wiring harness market from a low-cost strategic market to a cost-effective market with higher technical content." Recently, Zhang Jingtang, chairman of Tianhai Group, commented on the current status of the automotive wiring harness industry. "The development of new energy vehicles has indeed brought new opportunities to the upgrade of wiring harness technology." In the interview, many industry insiders gave similar answers. At the same time, the electrification and intelligence of automobiles have also promoted the vigorous development of the wiring harness industry, and a new wave of upgrades of wiring harness technology, processing technology and processing equipment is accelerating. In addition, the standardization process of high-voltage wiring harnesses is also progressing steadily. Recently, the National Electric Vehicle High-voltage Wiring Harness and Connector Standards Seminar hosted by the Automotive Standardization Institute of China Automotive Technology and Research Center was held, which means that high-voltage wiring harnesses are one step closer to standardization. Judging from the reporter's interview, automotive wiring harnesses are developing in the direction of high voltage, lightweight and standardization.

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High-voltage wiring harness technology is the focus of research. Compared with traditional fuel vehicles, hybrid electric vehicles, especially pure electric vehicles, in addition to the 12V circuit system, there is also a circuit system with a voltage exceeding 300V that is mainly used in power drive systems. High-voltage wiring harnesses are needed in this system to connect units in each circuit. Therefore, the high-voltage wiring harness is not only a key component of the high-voltage electrical system of new energy vehicles, but also an important guarantee for the safe and reliable operation of new energy vehicles. "There is little difference between the low-voltage wiring harness of new energy vehicles and the wiring harness of fuel vehicles. The main difference lies in the high-voltage wiring harness. The high-voltage wiring harness has undergone great changes in wiring harness materials, production processes and equipment." Sun Wei, director of parts development of Dezhou Jincheng Denso Co., Ltd. said that the requirements for material selection of high-voltage wiring harnesses have been significantly improved, and because it involves electricity safety, it is necessary to add a power-off switch or a maintenance switch on the battery pack, and the high voltage must be disconnected during maintenance operations. The development of high-voltage wire harness technology is also reflected in wire harness processing technology. The wire harness involved in battery pack voltage acquisition and temperature acquisition has high requirements for the crimping process. Due to the limitation of terminal materials in the large wire diameter part of the high-voltage wire harness, hydraulic equipment must be used instead of traditional stamping processes. In this regard, Sun Wei said: "New equipment must be used when processing parts with waterproof requirements. When the order quantity is small and it is not worth purchasing equipment, wiring harness factories generally require connector suppliers to provide semi-finished wiring harnesses that have been crimped for secondary processing to ensure quality." In addition, according to Zhang Jingtang, high-voltage wiring harnesses and aluminum battery wire crimping and other technologies are also developing rapidly. "Tianhai has successfully tackled key problems in aluminum battery wire technology, and the friction welding technology of copper-aluminum connection has been successfully applied to aluminum battery wire production process. At present, aluminum battery wire has been supplied to GM in batches. Li Yunlong, general manager of Changchun Yijia Technology Co., Ltd., has worked in Amphenol Kingstar Company for many years and is a veteran of the wiring harness industry. He told reporters that the current material used in automotive wiring harnesses is mainly copper, so in terms of weight reduction, in addition to reducing the cross-sectional area, aluminum materials lighter than copper are used. "The use of aluminum wires is also one of the future development trends. Some wiring harnesses on the roof of a well-known model use aluminum wires. At present, some domestic wiring harness enterprises are developing related technologies." Li Yunlong said, "The price of aluminum is about one-third of that of copper. Once aluminum wires can be applied in wire harnesses, it can not only reduce weight, but also effectively improve cost performance." Wire harness industry standards urgently need to establish the current new energy vehicle wiring harnesses and connectors have no relevant industry standards and national standards, resulting in uneven quality of related products. Taking connectors as an example, large and medium-sized enterprises basically have their own production experience and standards, but there are also some workshop-style enterprises that compete for the market at price, and the quality is difficult to guarantee. At present, China is in the period of large-scale promotion and application of electric vehicles, so it is particularly important to formulate and implement a unified high-voltage wiring harness and connector standard for electric vehicles. Li Yunlong said that the wiring harness of an OEM that was the first to develop new energy vehicles in China developed earlier and has mastered many patents for new energy vehicle wiring harnesses. Therefore, domestic wiring harness companies currently adopt the new energy vehicle wiring harness standards of this OEM. According to the reporter's understanding, specific standards for new energy vehicle wiring harnesses are currently being formulated, and some wiring harness companies are still adopting the GB/TS29106 standard for the time being. The standardization of high-voltage wiring harnesses will lay a solid foundation for the entire industry to enter the market for large-scale application. In addition, although some independent enterprises in China have made progress in the development of high-voltage wiring harnesses and lightweight technologies, some core technologies and equipment are still in the hands of foreign brands. For example, the maintenance switch technology and market of battery packs are basically monopolized by major international brands, and the price is very high. Therefore, while following the standards, enterprises also need to pay more attention to technological upgrading and stride forward on the east wind of development.

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