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An electric drivetrain of an HEV or EV consists of a wide variety of electronics such as high-voltage battery and motors. They are connected by high-voltage wiring harness for power transfer.
A wiring harness is an organized set of wires, terminals and connectors that run through the vehicle and relay information and electric power, thereby connecting a variety of components. Power and information travel through this delicate network.
The wiring harness in the vehicle is one of the heaviest and most expensive individual parts of a car (after the engine and transmission). In addition, the vast range of variants of today’s vehicle models requires a tailor-made cable system for almost every possible configuration as there is considerable change in various systems from vehicle to vehicle
Electric vehicles require additional expensive high-voltage lines for AC-DC charging, high-voltage batteries and, traction as well as special wiring for the high-voltage battery and the battery management system. GM is bringing about wireless battery management system in their new electric vehicle platform Ultium.
To know more about Global Automotive Wiring Harness Market, read our report
The changes in vehicle electronics will also result in a variety of changes in cable and cable channels:
In future data-driven business models which is gaining traction right now across manufacturers, some functions may only be temporarily enabled via OTA software updates.
In the case of electric vehicles, this can also include the motor performance. For car manufacturers to be able to implement such functions, the cabling must be designed for the maximum possible performance, even if this is rarely required at all due to the uncertainty of usage and also preparing for shifts in business models at any time
In addition to energy recovery and some other auxiliary technology, the bigger battery is the car’s important design ideas, so proper body layout, sufficient interior space, and apt safety features also put forward a higher design requirement. Soft, high bending radius of the wiring harness on the compact installation space is particularly important.
Thin-walled wire is a good choice for improving the softness of the wiring harness and reducing the space occupied by the wiring harness. However, compared with the thick insulation wall wire, its wear resistance, temperature and pressure resistance will achieve a higher performance claim.
Performance check for electric wire harness
Harness passes through many areas where it requires protection against heat, dust, moisture etc. Wire harness protection prevents damage caused by wire vibration damage, abrasions and incidental contact with other pieces of heat-producing equipment.
Thermal management tubes and sleeves are designed to operate under high temperatures and provide fire resistance under extreme conditions. The tubes and sleeves must be difficult to ignite, and they must self-extinguish promptly. The most common types of cable and wire protection are
A typical wiring harness drawing has cable lengths, component view, grommet, connector specifications and inline connectors.
Up until this point, the Leoni simulation process had difficulty keeping up with the number of iterations required to determine the ideal location for our harnesses. Design Space Exploration, the main component of this new strategy, employs an optimization algorithm to repeatedly approach the best harness design in a pre-specified space.
They have accelerated their procedures to be completed in less than 24 hours thanks to this new strategy, giving them more time to align with clients on data quality.
The use of a simulation toolchain is already integrated into routine business operations. It covers a broad range of tasks, including electrical wire dimensioning for harnesses, designing mechanical components and their structures, placing and cooling electronics PCBs properly, and designing injection tooling to assure proper moulding procedures.
Additionally, they have begun the dynamical simulation of certain important harness routing, such as door and trunk opening, driveline and axle connection, etc. The objective is to guarantee the proper performance and eliminate any chance of clinch, break, etc. by ensuring the suitable positioning and qualities, such as harness length.
A precise grasp of the various cables to model serves as the foundation for the cable simulation. In order to extract all cable parameters based on laser measurement and with high accuracy, such as bending qualities, LEONI has invested in a characterisation device called Mesomics.
The cable simulation models that will be used in projects can be tailored using these parameters, which are integrated into the database.
Engineers will route the harnesses according to guidelines and their own experience in a project using the 3D mechanical design and environment to simulate tensions and bending radius.
An derived fatigue index from the simulation is shown as a traffic light to draw attention to unsafe circumstances. Up until a suitable routing is reached, changes to the fixation points, length, etc., will be evaluated iteratively.
To know more about Global EV Connector Market, read our report
The Global Electric Vehicle Wiring Harness Market is a small derivative of the automotive wiring harness market. In 2021, the market size was estimated at $XX Million growing at –% CAGR till 2027.
Suppliers in western Ukraine have been shuttered by the Russian invasion, forcing them to limit output, and carmakers such as Volkswagen, BMW, and Porsche are battling to secure critical wire harnesses.
The item, which is used to organise kilometres of vehicle wires, has impacted vendors such as Leoni, Fujikura, and Nexans, as well as major carmakers. Some assembly plants of World No. 2 carmaker Volkwagen have already experienced delivery problems, while Porsche’s premium division has halted production at its Leipzig factory.
BMW, a competitor, has also been impacted. Our manufacturing will be disrupted due to supply shortages, BMW warned in a statement.
In the ordinary car, a wire harness is a critical combination of components that neatly bundles up to 5 kilometres of cables. Vehicles cannot be created without them because they are unique to each automobile model.
Suppliers such as Leoni, which has two wire harness manufacturers in western Ukraine, are scrambling to make up for production losses and disruptions in two plants in Stryi and Kolomyja, which have been sparked by Russia’s action against Ukraine.
Leoni stated that a task team had been constituted to assess the situation. Suppliers such as Germany’s Forschner, Kromberg Schubert, Prettl, SEBN, and Japan’s Yazaki have built up a sizable wire harness production sector in Ukraine, which also has a competent workforce, to lower prices and better compete in the global automotive industry.
Automotive businesses have invested in plants, with many, but not all, making wire harnesses, according to UkraineInvest, the Ukrainian government’s investment promotion bureau.
These plants are adjacent to automotive factories in Germany and multinational carmakers’ manufacturing hubs in central Europe. According to industry sources, increasing capacity at alternative sites in suppliers’ networks might take months, requiring factory space, machinery and tools, people, and money.
Aptiv Plc, an auto components manufacturer, spent months doing just that before the invasion, transferring high-volume production of car parts out of its two Ukrainian sites ahead of probable hostilities.
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