Wire harness manufacturing technology includes techniques for connecting wires, braiding, weaving, and wrapping. It also involves automation, digital twin technology, and software. Connecting wires Crimping: Deforming a metal connector to grip a wire;Soldering: Melting a filler metal to join metallic surfaces;Gluing: Connecting wires with glue;

Development Trends of Automotive Wiring Harness Industry

The rise of electric vehicles (EVs) is a major force in automotive wiring innovations. EVs and hybrids require complex wiring systems to manage high-voltage electric drivetrains, batteries, and advanced electronics. These systems necessitate specialized harnesses that can handle increased voltage and intricate connections for electric propulsion. OEMs and startups alike must consider the number and sophistication of technology features they integrate into their vehicles as they have a direct effect on harness weight, bundle diameter, and cost.

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Orange Color 800VDC High Voltage Power Cable Low Current 40A 3POs 4POs 5POs Waterproof EV HVIL Connector for Vehicle

Automotive Connecting cables Quality Inspection

UL Solutions offers testing services for various types of automotive cables used in the industry over a wide range of extreme temperatures. When it comes to cars, trucks, and other vehicles, wiring plays a huge role in keeping everything running smoothly. Automotive wiring isn’t just about connecting parts; it’s about ensuring safety, durability, and performance. Whether it’s powering your car battery, keeping your music crisp, or lighting up a trailer, the right wires make all the difference.

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Insulated U-Type Fork Red-Blue Terminal Set Electrical Wire Cable Crimp Spade Ring Connector Assortment

Comparison of Ultrasonic Welding and U-Shaped Crimping Wire Harnesses

Ultrasonic welding has more advantages in performance, durability, and environmental protection, but the cost is higher; U-shaped crimping is known for its economy and flexibility, and is suitable for conventional scenarios. The actual selection needs to be comprehensively evaluated in combination with specific process requirements, cost budgets, and product positioning.

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Inline Holder 14AWG Wiring Harness with ATC, ATO 30Amp Blade Automotive Fuse Holder

Blade Fuse Kit assembly for Automotive Wiring Harnesses

Most vehicles today use blade fuse Kit (also known as spade fuses or plug-in fuses), and there are five common types you’d typically find: While these fuses all have plastic bodies and metal legs, they all look physically different. Choose aftermarket ATO/ATOF, LP MINI, MAXI, MICRO, and MINI blade fuses and shunts when repairing electrical systems in gas, diesel, or electric vehicles wiring harnesses.

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