Custom New Energy Connection Harness

A custom new energy connection harness is a wiring harness specifically designed for electric vehicles (EVs) and other systems that utilize new energy technologies. It’s a tailored assembly of wires, cables, and connectors, designed to efficiently and reliably carry electrical power, signals, or data within a system.

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Customized new energy connection harness

New energy connection harness is a core component in electric vehicles, energy storage equipment and other fields. Its design and performance directly affect the efficiency of power transmission, system safety and reliability. The following is a comprehensive analysis of relevant technical points and industry dynamics:

1. Technical design and performance optimization
‌Buffering anti-seismic structure‌
The design of a two-way limit arc bracket, an elastic inner sheath and a steel wire armor mesh layer can improve the mechanical impact resistance of the harness. And the buffer cavity disperses external stress to reduce the risk of wire core damage.

‌Conductor and insulation material‌
The conductor is mainly made of high-purity copper or copper alloy, and the cross-section design needs to be optimized based on the current load to avoid overheating or voltage drop problems. The insulation layer uses materials such as cross-linked polyethylene (XLPE) to meet long-term stability in high voltage (such as above 1000V) and high temperature environments.

‌Electromagnetic shielding and protection‌
Electromagnetic interference (EMI) is suppressed through a copper braided mesh or aluminum foil shielding layer to ensure electromagnetic compatibility (EMC). The harness must have a protection level of IP67 or above and integrate a high-voltage interlocking circuit to ensure safe operation.

‌Thermal management solution‌
For high current scenarios, it is necessary to optimize the heat dissipation path of the conductor, and combine high temperature resistant insulation materials (such as silicone and Teflon wrapping) to reduce temperature rise and avoid material aging or thermal runaway.

2. Material and process innovation
‌Copper-aluminum composite connection technology‌
The copper-aluminum inlay cold pressing composite process solves the problem of dissimilar metal welding, reduces electrochemical corrosion and contact resistance, and improves the reliability and stability of aluminum wiring harnesses.
‌Lightweight trend‌
The application of aluminum conductors needs to balance conductivity while reducing the weight of the wiring harness. The copper-aluminum transition terminal becomes a key component, taking into account the characteristics of light weight and low resistance.

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3. Industry application and manufacturer dynamics
‌Market size‌
The high-voltage wiring harness of new energy vehicles is worth about 5,000 yuan per vehicle. As the penetration rate of new energy vehicles increases, the demand for wiring harnesses continues to grow.

‌Manufacturer solution‌
‌KUBON‌: Provides a wiring harness assembly with an integrated high-voltage power distribution unit (HVPDU), combined with high protection and electromagnetic shielding design.
‌YAXUN Wire Harness‌: Customized production of new energy vehicle wire harnesses, including power cords, modification cords, waterproof fuse boxes and other components.
‌Luxshare Precision‌: The automotive business has grown significantly, and it has entered the high-voltage wire harness field to enter the Tier 1 supply chain.

IV. Standardization and testing requirements
The design must comply with standards such as IEC 60228 (conductor cross-section verification) and ISO 11452-2 (electromagnetic compatibility), and reliability must be verified through tests such as withstand voltage, vibration, and salt spray.