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The Impact of an Efficient Wiring Harness in Electric Vehicles

The Impact of an Efficient Wiring Harness in Electric Vehicles

An electric car may look similar to one that has a combustion engine; however, the uniqueness of its parts and components, such as the electric car harness, is a testament to the ingenuity that went into these modern innovations.

The exponential growth in sales of electric cars in the 21st century cannot be solely attributed to its popularity.

The vast array of benefits that electric cars can provide its owner is also another reason why many people nowadays opt for a greener mode of transportation.

Sales for electric cars rose by 43% in the year 2020 and are still showing potential growth as we go further into the future.

But aside from its environmental sustainability, what makes an electric car so great?

The answer lies within its innovative design and modern components. An electric car is built with an electric car harness that is quite different from what you will find in a vehicle with a combustion engine.

Since each functional command in an electric car is signaled through its wiring harness, a more complex and unique electric car harness design is installed in each model.

The modern method of wiring a harness for an electric car directly impacts the way it performs.

Since everything is programmed to function accordingly, electric vehicles are proven to be more responsive and easier to maneuver than a typical car with a combustion engine.

Benefits Made Possible Through Efficient Electric Car Harness Design

Advancements in technology have not only opened many opportunities for electric car manufacturers in terms of technical versatility.

Trending innovations that can only be found in electric vehicles have also been considered as marketing opportunities that consumers seem to love.

Most of these cool, unique features are made possible through the wiring harness that runs through the vehicle.

Every year, companies release new models of electric vehicles that surpass the abilities of their predecessors so additional complex wiring solutions are necessary to accommodate these improvements.

Improved Weight and Mobility

For a car with a combustion engine, the lighter the weight, the less fuel it tends to consume.

The same can be said for electric vehicles. A lighter car tends to require less frequent charging.

However, since an electric vehicle heavily relies on an electric car harness, more wirings and components are usually installed within a harness.

This can greatly impact the weight of the vehicle so electric manufacturers constantly seek better and more lightweight materials that can cater to its mobility efficiency. 

Intelligent Driving

One of the amazing features of an electric vehicle is its artificial intelligence system.

Manufacturers nowadays continuously strive to develop high-quality cars with advanced A.I. capabilities.

Companies also try to keep up with technological trends such as autopilot and facial recognition functions that are made possible with intricate electric car harness designs.  These innovations in the electric car industry require additional wirings and components made to fit the wiring harness without adding too much weight. 

Low Maintenance Requirements

Since most electric cars heavily rely on wiring harnesses to achieve optimum performance, most people think that repairs and maintenance might be extensively difficult. However, wire harnesses actually make maintenance and repairs more convenient. An electric car harness is typically made up of subsidiary harnesses that connect to the main system. This means that instead of having to replace multiple wires just to resolve a single problem, parts can be replaced only within the specific area where the problem was diagnosed.

Increased Mobility

Since each function of an electric car is mostly controlled by its harness, the interactions between each component are more streamlined through the efficient wiring system running through the car. Electric cars are said to be more responsive and easier to control compared to cars that run on combustion engines. 

Cost Efficiency

Although electric cars are generally more expensive than conventional vehicles, it’s a guaranteed wise investment with all the money you can save in the long run. As aforementioned, minimal maintenance and repairs are required when an efficient electric car harness is installed in a car. Another factor, of course, is the money that is generally saved on fuel consumption. 

Typical Components of an Electric Car Harness

Even though electric cars require a more complex and sophisticated wiring system, most of the parts and components that make up an electric car harness are similar to ones that you would find inside a vehicle with a combustion engine. However, the materials may differ and may technologically be more updated in terms of durability and sustainability. 

Since most electric car manufacturers pride themselves on innovation and technological advancements, continuous progress to seek better raw materials for parts like wiring insulation is always a priority. Here are some common components that make up an electric car harness.

  • Insulation

The wiring insulation is an indispensable part of any kind of electrical setup. It is the tubing that wraps around the wires to protect them from external elements that may harm the system as a whole. There are numerous kinds of insulation materials and each of them works efficiently in specific situations and environments. 

For car harnesses, two common types of insulation materials are XLPE (Cross-Linked Polyethylene) and PVC (Polyvinyl chloride). The big difference between these two kinds of insulating materials is their ability to withstand high temperatures. An electric car harness with XLPE insulated wires can withstand extreme heat. However, both kinds of insulations have a voltage rating of 50 volts.

  • Terminals

Much like the insulation in an electric car harness, terminals play a key role in protecting the harness from any short circuits. They are responsible for terminating a conductor to a specific component and establishing a connection. Terminals can also be made of different materials depending on the electric car harness manufacturer’s design. They are typically made of alloy, metal, silicon, or carbon.  

It’s also important to note that there are several types of terminals that are made for specific functions. Terminals may come in different sizes and shapes such as a bullet, hook, spade, flagged, and quick-disconnect.

  • Connectors

Like Terminals, there are different types of connectors for an electric car harness. They’re designed according to function and the environment determines the kind of connector necessary for the wiring harness. 

Factors such as temperature, contaminants, and constant vibrations need to be considered when choosing the right type of connector. Depending on the design requirements, manufacturers can choose between a broad range of designs that are most suitable for the electric car harness.

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