Demystifying Automotive Wiring Harnesses: Types of Connectors and Design Principles

With the increasing complexity and intelligence of automotive electrical systems, the design of wire harness connectors is becoming more and more exquisite and powerful. Modern wire harness connectors use advanced materials and technologies, such as high-performance plastics, precision mold manufacturing, automated assembly, etc., to improve the reliability, durability and safety of wire harness connectors. Compared with traditional fuel vehicles, the electrical system of energy vehicles is more complex, involving high voltage power transmission, data communication and control signal transmission and other aspects. As an important node in the electrical system, the wiring harness connector is responsible for connecting various electrical components to ensure the stable transmission of power and signals. Therefore, the performance and quality of wire harness connectors directly affect the safety, reliability and performance of new energy vehicles.

What Is Wiring Harness in Automobile

The harness cable connector is similar to the neural network of new energy vehicles, connecting various electronic and electrical components, so as to achieve power transmission, signal transmission and data exchange, making the functions of new energy vehicles normal operation. Wiring harnesses are divided into low-voltage wiring harnesses and high-voltage wiring harnesses, low-voltage wiring harnesses are mainly responsible for controlling signals, making the equipment in the car operate normally, without the passage of large currents, while high-voltage wiring harnesses are responsible for transmitting high-voltage electrical energy, providing energy for the batteries and motors of new energy vehicles

Types of Connectors Used in Automotive Wiring Harness

In addition to the distinction by the size of the current, the connection method of the wire harness is also an important basis for classification. Common connection methods include welding, crimping, and splicing. Each connection has its own unique characteristics and usage scenarios. For example, the welding harness has high strength and stability, and is suitable for parts that need long-term stable operation; The crimped harness has the characteristics of high efficiency and convenience, and is suitable for the parts that need quick connection; The plug-in harness is flexible and can cope with a variety of complex connection needs.

How to Design Automotive Wiring Harness Connectors

New energy high voltage wire harness plug connectors need to consider a lot of factors in the design and production process, such as high temperature resistance, electromagnetic interference resistance, vibration resistance and other factors, from the beginning of the project to the landing need to go through dozens of stages, mainly summarized as concept, planning, development, verification, release, life cycle six stages, concept stage according to the relevant standards and customer needs to propose a concept plan. In the planning stage, I conducted research and analysis on the market, competitive products and mainstream technologies; in the development stage, I issued a formal design scheme, continuously improved the samples through ACE simulation design technology; in the verification stage, I verified the products and processes of the samples; when the samples were approved by customers, mass production began to be put into the market; continuous optimization and improvement were carried out in the subsequent lifecycle of the vehicle products to control costs.



As a key accessory linking various important components of new energy vehicles, the wiring harness connector ensures the safe and reliable operation of new energy vehicles. With the rapid development of new energy vehicles, wire harness connectors are also constantly improving, the future wire harness connectors will be more lightweight, intelligent, and there will be further improvements in safety and environmental protection.