How to balance the needs of lightweight and high strength in customized electrical wiring harness?
Publish Time: 2025-06-18
In the field of modern industry and automobile manufacturing, customized electrical wiring harness is a "neural network" connecting various electronic devices, and its performance directly affects the operating efficiency and safety of the whole vehicle or machine. With the advancement of technology and the improvement of energy conservation and emission reduction requirements, customized electrical wiring harness not only needs to have good conductivity and stability, but also must achieve lightweight design to adapt to emerging development trends such as new energy and intelligent driving.1. Material innovation: the basic guarantee of light weight and high strengthThe key to achieving the coexistence of lightweight and high strength in customized electrical wiring harness lies in the selection and optimization of materials. Traditional wiring harnesses mostly use copper core conductors and PVC insulation layers. Although they have good conductivity, they are heavy overall and easy to age in high temperature environments. In recent years, with the development of new materials, aluminum core conductors, copper-clad aluminum conductors and high-performance composite insulation materials have gradually been applied to wiring harness manufacturing.For example, copper-clad aluminum conductors combine the good conductivity of copper and the lightweight characteristics of aluminum, which greatly reduces the weight of the wiring harness while ensuring the current transmission efficiency. In terms of the insulation layer; new materials such as carbon fiber reinforced plastic (CFRP) not only have excellent temperature resistance and flexibility, but also effectively resist wear and chemical corrosion, thereby improving the overall strength of the wiring harness.In addition, some high-end models or aerospace fields have begun to try to use carbon fiber reinforced plastic (CFRP) as the outer sheath material of the wiring harness, which not only further reduces the weight of the wiring harness, but also enhances the tensile and impact resistance.2. Structural optimization: scientific layout improves performanceIn addition to material innovation, the structural design optimization of electrical wiring harness customized is also an important means to achieve lightweight and high strength in parallel. Through reasonable wiring path planning, hierarchical integration and modular design, redundant length and repeated wiring can be effectively reduced, and the overall quality can be reduced.For example, the modular wiring harness structure integrates the originally scattered lines into multiple functional units, which not only reduces unnecessary connection nodes, but also improves assembly efficiency and system stability. At the same time, using flat cables instead of round cables is also an effective way to reduce weight. It not only saves more space, but also improves bending flexibility, which is suitable for complex installation environments.In terms of high strength, by strengthening key parts, such as using a braided shielding layer, a double-layer sheath structure or a local thickening process, the compression and bending resistance of the harness can be significantly improved without increasing the overall weight.3. Manufacturing process upgrade: improving consistency and reliabilityAdvanced manufacturing technology is an important support for ensuring that lightweight harnesses have high strength. Traditional manual assembly methods are difficult to meet the increasingly complex needs of harnesses, while automated production technology can achieve higher precision and consistency.For example, fully automatic wire stripping and crimping equipment can complete wire cutting, stripping, crimping and other operations in a very short time, avoiding human errors and improving connection reliability; laser welding technology can be used for high-precision terminal welding, making the joints more secure and with lower contact resistance.In addition, injection molding technology is also widely used in harness processing. Multiple components are integrated together through one-piece molding, which not only improves the sealing and protection level, but also enhances the mechanical strength of the overall structure.4. Application scenario adaptation: Customization on demand has more advantagesDifferent industries have different requirements for customized electrical wiring harness, so in practical applications, customization on demand has become an important strategy to achieve a balance between lightweight and high strength.In the field of new energy vehicles, in order to meet the high-frequency signal transmission requirements of battery management systems (BMS), motor controllers, etc., manufacturers usually choose lightweight high-speed data harnesses with high-strength outer sheaths to ensure efficient operation in limited spaces; in the field of aerospace, more attention is paid to the extreme temperature resistance, radiation resistance and fire resistance of the harness, and high strength goals are achieved by selecting special alloy conductors and ceramic-based insulation materials.In summary, customized electrical wiring harness needs to find the best balance between lightweight and high strength, which cannot be solved by a single technology, but requires coordinated optimization from multiple dimensions such as material selection, structural design, manufacturing process, and application scenario matching. Only by continuously promoting technological innovation and industrial upgrading can we truly create a lightweight and strong customized electrical wiring harness solution and provide stronger support for modern manufacturing.
