What is the difference between wiring harnesses in the field of new energy vehicles and traditional automotive fields?

In the rapidly changing automotive industry, new energy vehicles have emerged as a rising force, gradually changing people's modes of transportation and the industrial landscape. As a key "neural network" in the automotive electrical system, automotive wiring harnesses play an extremely important role in both traditional and new energy vehicles. However, due to the significant differences in power sources and electrical systems between the two types of cars, the wiring harnesses they are equipped with also have many differences.

Voltage and current:

New energy vehicles: New energy vehicles generally use high-voltage platforms, such as the common 300-600V or even higher, with currents reaching 300A or more. For example, the battery pack voltage of Tesla Model S can reach hundreds of volts, and its wiring harness needs to transmit strong electrical energy to drive high-voltage equipment such as motors.

Traditional cars: The electrical system of traditional cars is mainly based on low-voltage platforms of 12V or 24V. For wires with a withstand voltage level of less than 60V and relatively low current, it is mainly used for power supply and signal transmission of low-voltage equipment such as car lights, speakers, and windows.

Wire diameter and quantity:

New energy vehicles: In order to withstand high voltage and high current, the wire harness diameter of new energy vehicles is relatively large. Moreover, due to the more complex electrical system of new energy vehicles, there are many devices that need to be connected, such as battery packs, motors, chargers, DC/DC converters, etc., so the number of cables is also relatively large.

Traditional cars: Traditional car wiring harnesses have relatively small diameters and quantities because their electrical equipment has lower power and voltage requirements and does not require the transmission of large amounts of electrical energy.

Protection and sealing:

New energy vehicles: The wiring harness of new energy vehicles, especially high-voltage wiring harnesses, needs to be matched with high-voltage connectors and have high sealing and waterproof levels, such as IP67, IP69K, etc., to prevent moisture, dust, etc. from entering the wiring harness system and causing electrical faults or safety accidents. For example, at the charging interface of electric vehicles, the wiring harness needs to be well sealed to ensure the safety of charging in various harsh environments.

Traditional cars: The protection level of traditional car wiring harnesses is relatively low because their working voltage and current are low, and their sensitivity to the environment is relatively weak.

Function and purpose:

New energy vehicles: The wiring harness of new energy vehicles not only needs to transmit electricity, but also undertakes the tasks of data transmission and signal control, such as information exchange and collaborative work between battery management systems, motor control systems, charging systems, etc., requiring the transmission of a large amount of data and control signals through the wiring harness.

Traditional cars: The main function of traditional car wiring harnesses is to supply power to electrical equipment and achieve simple signal transmission, such as controlling the on/off of car lights, honking of horns, etc. The functions are relatively simple.

In summary, there are significant differences between new energy vehicle wiring harnesses and traditional automotive wiring harnesses in multiple dimensions. These differences are caused by the transformation of automotive power forms and the increasing complexity of electrical systems. With the continuous advancement of new energy vehicle technology, wire harness technology will also continue to innovate to meet the higher performance requirements of new energy vehicles. For automobile manufacturing companies, wire harness suppliers, and related researchers, accurately grasping these differences is necessary to seize the opportunity in the booming development of new energy vehicles.

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