A 5-kilometer-long automotive wiring harness

ypically, the length of a family car doesn't exceed 5 meters, while its width is approximately 1.5 meters. Astonishingly, within this tiny space, the wiring harness used can be as long as 5 kilometers, which is capable of winding around the car 384 times. But why on earth does a car need such an extremely long wiring harness? And just how crucial is it to reduce the length of the wiring harness for the automotive industry? Today, let's delve into the wiring harness revolution in the automotive industry.

If we compare a car to a human body, then the engine is the heart, the frame is the skeleton, and the tires are the feet. Just as the heart and limbs of a human body need to be connected by nerves and blood vessels, various components of a car also rely on different kinds of wires and pipes for connection. The wiring harness, in fact, serves as the nerves and blood vessels of a car. During the operation of a car, every functional instruction given by the owner is transmitted through the wiring harness. Merely within the engine compartment of a fuel vehicle, there are wiring harnesses stretching 5 to 8 meters long. These wiring harnesses connect all kinds of sensors and actuators of the engine, such as the crankshaft position sensor, camshaft position sensor, fuel injector, ignition coil, and also supply power and transmit signals for equipment like the generator and starter.

For instance, the wiring harness links the car battery to the starter. When the driver turns the ignition key, the current is transmitted to the starter through the wiring harness, enabling the engine to start smoothly. Compared with traditional fuel vehicles, electric vehicles are equipped with complex and precise high-voltage components, high-voltage connectors and other high-voltage electrical parts. For these electrical components to operate normally, a large quantity of high-voltage wiring harnesses are also required. Electricity needs to be supplied, signals need to be transmitted, and functions need to be integrated by the wiring harness. Although it may seem inconspicuous, the wiring harness is actually vital to the performance and safety of a car. It truly is a case where a single move can affect the whole situation.

These wiring harnesses crisscross and densely spread throughout the car, ranging from 3 to 5 kilometers in length. Such long wiring harnesses have brought no small amount of trouble to the production, use and maintenance of cars. Most of the wiring harnesses can only be installed manually, involving various processes such as docking, perforating and wiring. With more and longer wiring harnesses, the installation difficulty and time will increase, slowing down the overall production efficiency and raising the production cost. In the cockpit, the situation is no different. Once damaged, maintenance and renewal can be rather troublesome.

If the wiring harness is too long, the circuit layout will become more complex. When there are too many wiring harnesses crowded together, it is not conducive to heat dissipation and may also cause signal interference. One more wiring harness usually means two more connections, which also increases the risk of loose connectors. Conversely, if we can reduce the wiring harness, the benefits will be numerous. It can not only lower the difficulty and cost of car production and maintenance, but also help to reduce the vehicle's weight and improve its energy efficiency and performance. Never underestimate the wiring harness, as it can account for 3% - 5% of the total vehicle weight.