The development direction of automotive wiring harnesses
Release time:
2025-11-10
Competition among wiring harness manufacturers is intensifying. As products reach a certain stage of development, competitors will increasingly vie for supremacy within companies that are sizable, financially strong, and trustworthy. Smaller enterprises will be phased out. Wiring harness assembly is becoming increasingly concentrated in companies with strong technological capabilities. Since automotive wiring harnesses differ from ordinary wiring harnesses—particularly because they incorporate certain electronic components directly attached to the harness, such as sensors and hybrid thick-film circuits—these electronic components feature high technical complexity and place great emphasis on technical safety and reliability. As a result, the assembly process has moved beyond simple, conventional methods.
Competition among wiring harness manufacturers is intensifying. As products reach a certain stage of development, competitors will increasingly vie for supremacy within companies that are sizable, financially strong, and highly reputable. Smaller enterprises will be phased out. Wiring harness assembly is becoming increasingly concentrated in companies with strong technological capabilities. Since automotive wiring harnesses differ from ordinary wiring harnesses—particularly because they incorporate certain electronic components directly attached to the harness itself, such as sensors and hybrid thick-film circuits—these electronic components feature high technical complexity and place great emphasis on technical safety and reliability. As a result, the assembly process has moved beyond simple, conventional methods.
It is reported that a mid-range sedan features nearly a thousand connection interfaces, more than thirty microprocessors, and several hundred pairs of connectors, with the total length of wires used reaching between 1,500 and 2,000 meters. With the advancement of IT technology, the emergence of the E-concept car has pointed toward a future of vehicle networking and modularity. Networked clusters are already on the horizon, poised to trigger a second major leap forward in wiring harness manufacturing technology. The functions of wiring harnesses have expanded from merely transmitting ordinary signals to encompassing data transmission as well.
Moreover, due to the limitations of wire-based signal transmission, optical cables will be extensively adopted, ushering in a third major leap in automotive wiring harness manufacturing technology. Optical cables offer numerous advantages, including high transmission speeds, large data capacity, compact size, strong confidentiality, and excellent resistance to interference. They will soon become the preferred material for future automotive data processing and exchange, propelling power and signal distribution systems into a new stage of development. Currently, BMW’s D-segment sedans already utilize optical cable technology, and Japan is closely following suit, having entered the stage of actual vehicle integration. The current main development trends in wiring harness technology include multi-channel transmission technology. This technology enables multiple signals to be transmitted over a single common medium, allowing electronic control units to share information and eliminating the need for individual wiring connections. The application of this new technology simplifies wiring harness connections, resulting in a more compact structure that not only reduces weight but also lowers costs. Since information is widely shared rather than simply duplicated, fault diagnosis becomes more accurate, engineering changes are faster, and defect repairs are more convenient.
Multi-station connection technology refers to an internal connection system capable of linking multiple smart devices. This technology not only enables shared battery power and reliable grounding but, more importantly, facilitates data sharing. As a result, this technology significantly reduces the number of module inputs and outputs, minimizes the count of components, and simplifies the assembly of modules and wiring harnesses. By drastically cutting down on the number of connection points, both the production cycle and manufacturing costs are noticeably reduced. The integrated electronic and electrical technology involves equipping modern vehicles with a centralized electrical box—known as the BEC (Bussed Electrical Center)—that combines electronic and electrical functions. In terms of electrical functionality, the BEC acts like a miniature substation, efficiently distributing battery power to various circuits as needed. In terms of electronic functionality, it serves as a small-scale data-processing center, handling and transmitting diverse signals. With the increasing complexity of automotive functions and the widespread adoption of electronic control technologies, coupled with growing consumer demands for vehicle safety, comfort, and economy, the electrical configurations and functionalities in cars have expanded dramatically. Consequently, the number of electrical components has surged, and the wiring harnesses connecting these components have become increasingly intricate and bulky. To address these challenges, advanced vehicles now incorporate CAN bus architectures, utilizing multiplexing systems. Compared to traditional wiring harnesses, multiplexing systems greatly reduce the number of wires and connectors, making wiring installation much simpler.
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