High-voltage wiring harnesses are critical components of new energy vehicles. Their safety and reliability directly correlates with the performance and safety of the vehicle as a whole. The manufacturing process is complex and requires strict adherence to relevant standards and specifications to ensure quality.

 

Equipment for Manufacturing High-Voltage Wiring Harnesses

Specialized production equipment is necessary to meet the stringent technical requirements of high-voltage wiring harness manufacturing. Common equipment includes:

• Cable cutter: to cut wires into specific lengths.
• Wire stripper: to remove insulation from wires.
• Crimping machine: for crimping terminals onto wires.
• Assembly machine: to assemble wiring harnesses into their final product.
• Testing equipment: to test electrical and mechanical performance to ensure quality.

 

Sealing Measures for High-Voltage Wiring Harnesses

Various sealing methods such as wire sealants, heat shrinking tubing, and rubber components are used between high-voltage conductors and connectors to meet IP67 waterproof and dustproof requirements.

Examples of various seals and preventive measures are:

 

Seal spec. materials and production are completed in accordance with automotive manufacturers’ spec.

Rubber sleeve sealing protection (left) / U-shaped layout for wire harness protection (right)

 

Development Trends in High-Voltage Wiring Harness Production

As new energy vehicles continue to develop rapidly, the demand for high-voltage wiring harnesses will also grow. Manufacturing technology for wiring harnesses is also evolving. Some main trends include:

• High voltage and high current
• Lightweight and integrated layout
• “Smart” technology

 

The production of high-voltage wiring harnesses is a complex system engineering task that requires consideration of a variety of factors. To ensure quality and safety, strict adherence to relevant standards and specifications is necessary for high voltage wiring harness production equipment, processes, and production safety.

 

CTE Tech’s Wiring Harnesses for New Energy Vehicles

To meet the high-voltage wiring harness requirements of automotive manufacturers of new energy vehicles, CTE Tech has introduced a production line specifically for high-voltage wiring harnesses for new energy vehicles. This production line is fully equipped with features ranging from exploded-view drawings to product assembly, including stripping, crimping, assembly, and testing. The production line meets the requirements for customized harness manufacturing, but also satisfies different customers’ needs for new energy wiring harnesses.

 

1. High-Voltage Wiring Harnesses

As the main source for power transmission in new energy vehicles, high-voltage wiring harnesses have material and technical requirements that are stricter than those of traditional wiring. CTE has produced various high-voltage wiring harness materials of different diameters that can handle wires ranging from 2.5mm² to 120mm² through fully automatic wire cutting and stripping equipment.

 

 

2. Specialized Production Equipment

The production process for new energy high-voltage wiring harnesses is strict in order to improve product quality and meet production requirements. CTE Tech has introduced a large amount of specialized production equipment to meet the equipment requirements of the high-voltage wire harness production process:

Wire cutting → Shielded wire processing → Snake tube cutting → Reverse threading → Crimping → Assembly → High and low voltage/waterproof testing → Finished product appearance inspection.

 

 

CTE Tech high-voltage wiring harness production lines include a variety of high-precision automatic/semi-automatic equipment

 

3. Production Testing Workstations

To achieve high quality manufacturing and ensure personnel safety for new energy production lines, CTE Tech has independently developed testing workstations to meet relevant quality testing requirements while ensuring safety. The testing workstation for CTE’s high-voltage production line can perform high voltage testing of up to max DC 6000V / AC 5000V / 40 mA, as well as insulation testing of up to max DC 6000V / 5GMΩ, and IP67-grade air tightness testing.

As for safety precautions, facial recognition, safety light curtains, and independently developed testing components ensure that every high-voltage wiring harness tester is fully protected.

 

The CTE Tech high-voltage wiring harness testing workstation has complete detection and safety protection measures

 

4. Finished Products