Introduction: Perfect Match Between Materials and Molds is Key
With the rapid growth of the New Energy Vehicle (NEV) market, battery and control system wiring harnesses have become a critical component for electric vehicle performance and safety. Wiring harnesses not only transmit power and signals but also directly affect vehicle reliability, efficiency, and lifespan.
As a professional manufacturer of precision molds, injection-molded parts, and various wiring harnesses, TSP is dedicated to providing high-quality battery harnesses, BMS wiring, and industrial control system harnesses for NEVs, ensuring products meet global safety and performance standards.
1. Overview of EV Wiring Harnesses
EV wiring harnesses are assemblies of cables and terminals designed for the battery management system (BMS), motor controller, and onboard power network. Key features include:
High current capacity: Supports high-current charging/discharging and drive system requirements
Lightweight design: Optimizes vehicle weight and increases driving range
Robust protection: Heat-resistant, abrasion-resistant, and EMI-resistant
Modular layout: Simplifies production, installation, and maintenance
Smart integration: Supports sensors and monitoring circuits for real-time status tracking
Case Study: TSP provided a custom BMS wiring harness for an EV manufacturer, achieving modular layout, improving installation efficiency by 35%, and reducing maintenance time by 25%.
2. Types and Applications of EV Wiring Harnesses
EV wiring harnesses can be categorized based on function and routing requirements:
Battery harnesses: Connect battery packs to the BMS, ensuring safe and efficient power delivery
High-voltage power harnesses: For motor controllers and drive systems, requiring high insulation and voltage tolerance
Low-voltage control harnesses: Transmit signals for dashboards, ECUs, and auxiliary systems
Charging system harnesses: Support fast/slow charging ports and communication
Custom BMS harnesses: Optimized for vehicle layout and battery safety
TSP provides full custom solutions tailored to specific vehicle models and battery system layouts, supporting both small-batch prototypes and large-scale production.
3. Design and Manufacturing Considerations
Key aspects for designing and producing EV wiring harnesses include:
Wire and terminal selection: High-temperature, low-resistance, vibration-resistant materials
Routing and protection: High-quality sleeves, bundling, and heat shrink to prevent wear, shorts, and chemical damage
Labeling and modularity: Clear numbering and modular design for easy maintenance and replacement
Testing and verification: Electrical performance, pull tests, thermal/humidity/salt spray tests for long-term reliability
Compliance with safety standards: ISO 6469, ISO 6722, UL, CE, IPC/WHMA-A-620
4. Technical Advantages and Industry Trends
TSP’s manufacturing process covers the full lifecycle: design → precision molds → cutting, stripping, crimping → bundling, sleeving → testing → mass production.
Technical Advantages:
High reliability ensures stable vehicle operation
Customizable and modular for different vehicle and battery layouts
Cross-industry applications: EVs, energy storage systems, industrial control
Lightweight materials improve range and efficiency
Integration of smart monitoring circuits enhances safety
Industry Trends:
High-voltage, lightweight, modular, and intelligent wiring harness designs are becoming mainstream
Harness materials are increasingly eco-friendly, heat-resistant, and anti-aging
Rapid EV development drives demand for high-performance harnesses
TSP continues to provide innovative solutions, helping global clients deliver efficient, safe, and intelligent electric mobility experiences.
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