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Last Updated: Apr 25, 2025 | Study Period: 2024-2030
A wire harness, also known as a cable harness or wiring assembly, is a collection of wires, cables, or subassemblies that are meant to carry signals or electrical power.
A simple Wire Harness may have as little as three discrete components, but more traditional harnesses contain many more wires and additional passive, and sometimes active, components.
An Electric bus wire harness is often confused with a cable assembly; the main difference between the two is that a cable assembly usually has just two ends while a wire harness has multiple branches/ends running off in many different directions with multiple terminations on each branch.
The wire harness streamlines the construction of these bigger components by including the wiring into a single unit, or many pieces, for "drop-in" installation. By combining all of the wires, cables, and subassemblies into a harness, the OEM or installer only needs to install one component.
Once a design has been determined, the process of creating a wire harness begins with the creation of a schematic, which is used to produce the manufacturing documentation and the harness's assembly board.
Once cut to the proper length, the wires are stripped to expose the uninsulated conductor and then fitted with any required terminals or connector housings. These wires and components then are put on the pin board and are bound together by any necessary straps, cable ties, cable lacing, sleeves, tapes, weaves of extruded string, or any combination of these.
To know more about Global EV Connector Market, read our report
| S No | Overview of Development | Development Detailing | Region of Development | Possible Future Outcomes |
| 1 | IPC to develop architecture standard for interconnectivity and harness processing in EV based Buses etc. | IPC International Inc. is at the forefront of developing best practices for automotive architectures through a collaboration with volunteers. IPC-9791: Electric Mobility Cable and InterconnectsâVisual Acceptability and Process Requirements, a new standard for electric vehicle wiring harnesses, cables and interconnects. | USA | This would enhance better EV harness Technologies and production |
| 2 | Wireless BMS Implementation of next gen battery requirements | new wireless battery management system concept -- which includes a proprietary wireless connectivity protocol, a set of electronic chips and is the first to demonstrate support for system-level functional safety compliance -- eliminates the need for this heavy, expensive, and maintenance-prone wiring, creating new opportunities in EV design. | USA | This would help in better presence and social responsibility on increased levels of requirements |
| 3 | Siemens approach to specialty cables for better harness efficiency | specialty cables will further reduce the weight, cost, and bundle diameters of harnesses. The number of cameras and displays will only increase in the future. OEMs must balance between using high baud rate networks that require specialty cabling and installing a greater quantity of lower baud rate networks, based on the resulting cost, weight, complexity, and risk of the harness. | USA | This would improve its presence and production capability of new generation system |
A wiring harness has many connectors that can serve as an extension to the main harness which allows routing to devices which are located beyond the reach of the main harness.
The electrical system of any vehicle performs the same function. To deliver and monitor electrical power to various devices and sensors while under control of the computer system or a passenger inside the car.
Electric bus component parts are increasingly requiring electronics to save space and satisfy other criteria as they continue to deliver sophisticated functionality.
Various manufacturers which specialize in the effective design and configuration of complicated circuits, develop wiring harnesses that significantly contribute to the development and advancement of vehicle manufacturers all over the world.
The wire harness in the vehicle is one of the heaviest and most expensive individual elements of a car, which is a little-known fact in automotive electronics and electronics (after the engine and transmission).
Considering the size and compartment of requirements to be in place for an electric bus, the costing is considerably higher.
Introduction of a more centralized computer architecture based on powerful domain computers rather than dozens of distributed ECUs; increased use of sensors with correspondingly higher data volumes within the vehicle and between the vehicle and the outside world and electrification of the drivetrain has been part of the much-required Electric bus module production lines.
Increasing need for connection and internet protocol in emerging and developed nations, as well as pent-up demand for automotive (particularly automobiles), are likely to boost the worldwide cable harness market.
However, the slowing economy and unpredictable raw material prices, as well as various regulatory measures, have hampered market expansion.
The Global Electric Bus Wiring Harness Market can be segmented into following categories for further analysis.
The Bus Wiring harness has been one of the most expensive components onboard the electric buses as it has been the main part of electrification requirements for better improvised automation.
Wire harnesses for Electric buses bundle multiple electric wires together and are routed in every corner of automobiles mainly for electric power supply and signal transmission.
There has been a recent change in the technological interventions within the wiring harness systems onboard the buses of electrification in the global market.
The recent harnesses are based on pressure welding multiple PCB built in connectors (smart connectors) to 3-circuit ribbon wire. It leads to reductions in wiring and weight by suppressing the number of servo motors that move doors for air outlet switching or inside air / outside air switching, etc., in air conditioners using smart connectors based on multiplex communication.
There has been a blended approach being adopted for the harness systems in the electric buses where in, the conventional and high-grade aluminum wires are adopted to exhibit higher strength and higher bending properties, which have been applied to the development of the high-strength aluminum harness.
The strength and bending properties of the newly developed "high-strength aluminum alloy wire" are higher than those of copper wire (twice higher than the standard aluminum wire). This allows thinning of the wire, and application to the vibrating and bending parts of the EV Motor and the powertrain requirements.
The Electrification of mobility in various parts of the globe has brought upon the much-required better ways of enhancing the electrical and electronic systems of a specific part or component in the electric vehicles.
With specific focus now moving upon adoption of EVs, the public transportation of Electric buses is being introduced into electrification to have a better impact on large-scale emission requirements.
Sumitomo Electric Wiring Systems has been part of the global manufacturing of the electric wire harness systems in the electric buses. Complying with the recent requirements of lower fuel consumption, safety, and riding comfort of the automobile, weight reduction of the wire harness (by 20-30 kg per vehicle) has become the most important trend in electric bus harness system improvements.
Instead of the copper wire which has been conventionally used, "high-strength aluminum alloy wire" is installed in the engine harness for the purpose of reducing weight and cost.
Furukawa Group has been involved in manufacturing the Electric wire harness systems for Electric buses which has been one of the most important products of dimensional requirements.
It has been involved In development of the sliding door harness which uses a flat cable with incredible flexibility and works with the opening and closing of slide doors.
The long slide seat harness houses a flat cable in accordance with seat movement with a large amount of slide. The Lightweight Sliding Door Harness that has significantly Durable against continuous bending by applying a flat cable. There is no degradation in performance even under environments of -40â (low temperature) to 85â (high temperature).
| Sl no | Topic |
| 1 | Market Segmentation |
| 2 | Scope of the report |
| 3 | Abbreviations |
| 4 | Research Methodology |
| 5 | Executive Summary |
| 6 | Introduction |
| 7 | Insights from Industry stakeholders |
| 8 | Cost breakdown of Product by sub-components and average profit margin |
| 9 | Disruptive innovation in the Industry |
| 10 | Technology trends in the Industry |
| 11 | Consumer trends in the industry |
| 12 | Recent Production Milestones |
| 13 | Component Manufacturing in US, EU and China |
| 14 | COVID-19 impact on overall market |
| 15 | COVID-19 impact on Production of components |
| 16 | COVID-19 impact on Point of sale |
| 17 | Market Segmentation, Dynamics and Forecast by Geography, 2024-2030 |
| 18 | Market Segmentation, Dynamics and Forecast by Product Type, 2024-2030 |
| 19 | Market Segmentation, Dynamics and Forecast by Application, 2024-2030 |
| 20 | Market Segmentation, Dynamics and Forecast by End use, 2024-2030 |
| 21 | Product installation rate by OEM, 2023 |
| 22 | Incline/Decline in Average B-2-B selling price in past 5 years |
| 23 | Competition from substitute products |
| 24 | Gross margin and average profitability of suppliers |
| 25 | New product development in past 12 months |
| 26 | M&A in past 12 months |
| 27 | Growth strategy of leading players |
| 28 | Market share of vendors, 2023 |
| 29 | Company Profiles |
| 30 | Unmet needs and opportunity for new suppliers |
| 31 | Conclusion |
| 32 | Appendix |
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