The wire harness industry, integral to sectors like automotive, communications, and industrial manufacturing, is embracing rapid technological advancements. Innovations in AI and automation are improving design precision and manufacturing efficiency.

Unlike conventional cables, EV high-voltage cables must withstand extreme temperatures (up to 175°C in some cases) and transmit high currents (up to 450A). Common insulation materials such as XLPE, silicone rubber (SIR), and thermoplastic elastomers (TPE) are selected based on their temperature resistance, flexibility, and mechanical properties.

HV wiring harnesses are critical components in EVs, ensuring safe and reliable power distribution. These harnesses undergo rigorous testing to meet stringent industry standards and guarantee performance in various conditions. Key tests include electrical performance checks such as dielectric withstand, continuity, and insulation resistance; mechanical durability assessments like tensile strength and vibration resistance; and environmental tests, including temperature cycling and humidity resistance. Additionally, tests for EMI and HVIL safety features are essential for ensuring safety. This comprehensive testing process is crucial for the durability, safety, and compliance of EVs, particularly in the challenging automotive and energy environments.

This article addresses the necessity and design of manual unlocking mechanisms in Guchen CCS2 DC charging sockets. It explains the technical background, highlighting the critical role of locking devices in preventing safety hazards during EV charging. Featuring solutions for both front-mounted and rear-mounted sockets, the article discusses how these mechanisms ensure safe, reliable, and user-friendly charging experiences, even during power outages or electronic lock failures.

Tesla's Low Voltage Connector Standard (LVCS) introduces a groundbreaking approach to simplifying low-voltage system interfaces, aiming for industry-wide adoption alongside the shift to 48V systems. Despite its simplicity, standardizing low-voltage connectors presents challenges rooted in supply chain dynamics, regional industrial practices, and the profitability of custom designs. Tesla’s LVCS design prioritizes cost efficiency and modularity, signaling a potential disruption in the market. However, achieving widespread standardization requires collaborative efforts from automakers and suppliers, as the industry grapples with the complexities of unifying high- and low-voltage interfaces.

It discusses the challenges posed by copper oxidation, the benefits of tin plating, and its cost-effectiveness compared to alternatives like gold, silver, and nickel plating.