The custom auto wiring harness can reduce the automotive wiring harness failure rate from the market standard of 0.5% to 0.02%, according to SAE International 2023 research report, The high-voltage system (800V) electromagnetic interference is reduced to 3mV/m (national standard limit 15mV/m) by the custom wiring harness design, and driving range is improved by 6.2%. Its modularity decreases the length of the harness overall by 34% (from 5km to 3.3km for a typical electric car), and its weight is shaved off by 22kg, or equivalent to a power savings of 0.8kWh over 100km. The case of a modified car manufacturer illustrates how by using the silicone insulated wire with a temperature resistance of 200 ° C, the lifetime of the engine room wire harness is extended from 5 years to 12 years and yearly maintenance cost is reduced by $2800.
precision adaptation features to improve system compatibility, Volkswagen ID.4 project by custom CAN FD wiring harness (transmission rate of 2Mbps), the automatic driving sensor delay compression from 18ms to 5ms. Its EMC design is according to the ISO 11452-4 standard, and the signal bit error rate under 100V/m field strength is below 10⁻⁹, 4 orders of magnitude above the general wiring harness. A hybrid product utilizes a patented high voltage Interlock loop (HVIL) that maintains the battery pack’s contact resistance level at 0.2mΩ±0.02mΩ, reducing the threat of thermal runaway by 89%.
From an efficiency of production aspect, the mechanized rate of production of bespoke wire harnesses is 1200 rods/hour (tolerance ±0.05mm), a 15 times increase from the manual production. Toyota TNGA platform data shows that its wire harness structure in modular form reduces end assembly time by half from 32 minutes to 9 minutes and reduces wiring harness interfaces by 68%. Its laser marking system (accuracy ±0.1mm) saved 100% traceability, an efficiency in processing incidents in recalls by 300%, saving $4.5 million.
Cost optimization dimension, topology-optimized special auto wiring harness to increase the material utilization ratio up to 98%, a new power vehicle company streamlined the wiring harness design cycle from 12 weeks down to 18 days. Its intelligent selection system can pair 300 types of connectors, and Volkswagen MEB platform reduces wire harness BOM costs by 19% through grouping terminal specs. Nexans’ aluminum core wire solution (61% IACS) saves 32% in harness cost while satisfying the ISO 6722-1 bend life requirement of over 50,000 times.
Frost & Sullivan says that the mean maintenance cost of a model with the custom auto wiring harness is lowered by 57%, and the failure-to-failure distance is increased from 150,000 km to 500,000 km. Its burning behavior meets the UL94 V-0 standard (burning rate ≤40mm/min), and the duration of the flame is ≥180 seconds in the battery thermal runaway test, which is a critical 45 seconds for occupant evacuation. These facts justify the non-substitutability of custom-designed wiring harnesses in maximizing vehicle performance, safety and economic value.