Company News

The Special Needs of New Energy Vehicles for Chinese Automotive Wiring Harnesses


With the proliferation of new energy vehicles, meeting their unique technical requirements has become crucial. As Konnra, we understand the importance of Chinese automotive wiring harnesses in new energy vehicles and are dedicated to providing innovative solutions in this field. The needs of new energy vehicles for wiring harnesses extend beyond power transmission, encompassing the safety of high-voltage cables, the stability of data transmission, the lightweight nature of materials, and the integration of intelligent management systems. The technical complexity and precision required by these needs demand continuous innovation and optimized design. By employing the latest material science and advanced manufacturing processes, Konnra can help customers overcome these challenges, ensuring their new energy vehicles achieve optimal performance, safety, and sustainability. In this blog, we will delve into the specific needs of wiring harnesses for new energy vehicles and demonstrate how Konnra, through technological innovation and optimized design, meets these complex requirements. Let’s explore together how to provide the best wiring harness solutions for new energy vehicles.

High-Voltage Wiring Harness Design and Application

New energy vehicles, especially electric and hybrid vehicles, use electric drive systems that require high-voltage power transmission. Therefore, the design and application of high-voltage wiring harnesses become a key technology. Unlike the low-voltage wiring harnesses used in traditional fuel vehicles, electric vehicles need to transmit higher voltage power, usually above 400V. High-voltage wiring harnesses must have excellent insulation performance and electromagnetic interference resistance to ensure safety and reliability.

The material selection for high-voltage wiring harnesses is crucial, typically using materials resistant to high voltage and high temperature, such as cross-linked polyethylene (XLPE) or silicone rubber. These materials can withstand high voltage and maintain stable performance in high-temperature environments. Additionally, the structural design of high-voltage wiring harnesses is also critical, often using a multi-layer structure, including shielding layers, to reduce electromagnetic interference with other electronic devices.

Lightweight Requirements

To improve the range of new energy vehicles, the lightweight design of the vehicle is a key factor. As part of the overall vehicle weight, the lightweight requirements of wiring harnesses are equally important. Traditional wiring harnesses mainly use copper materials, which, while having excellent electrical conductivity, are relatively heavy. To reduce weight, aluminum alloy is gradually being used in wiring harness manufacturing. Aluminum alloy is lightweight and has good electrical conductivity and corrosion resistance, making it suitable for application in new energy vehicles.

In addition to material selection, optimizing the layout and design of wiring harnesses can effectively reduce their weight and usage. Through refined design and advanced manufacturing processes, new energy vehicles can achieve lightweight wiring harness systems, thereby improving overall vehicle energy efficiency.

Data Transmission Wiring Harnesses

New energy vehicles integrate numerous electronic control units (ECUs) and sensors, which require data transmission through wiring harnesses. Compared to traditional fuel vehicles, new energy vehicles have higher requirements for data transmission stability and speed. CAN bus and Ethernet technologies are widely used in new energy vehicles to achieve communication between various electronic devices.

To ensure data transmission stability, data transmission wiring harnesses need to have good shielding designs to prevent electromagnetic interference from affecting data transmission. The design of wiring harnesses should consider not only power transmission but also data transmission needs. Through reasonable structural design and material selection, the reliability and speed of data transmission can be ensured.

Heat Dissipation and Temperature Resistance

The batteries and motors of new energy vehicles generate a lot of heat during operation, placing higher demands on the temperature resistance of wiring harnesses. To ensure the stability and safety of wiring harnesses in high-temperature environments, high-temperature-resistant materials such as high-temperature nylon and polyether ether ketone (PEEK) are required. These materials have excellent high-temperature resistance, good mechanical strength, and chemical resistance, allowing them to work stably in harsh environments for a long time.

Besides material selection, the heat dissipation design of wiring harnesses is also an important consideration. By increasing the heat dissipation surface area of wiring harnesses or using thermally conductive materials, effective heat dissipation can be achieved, preventing damage due to overheating.

Modular Design

To simplify the assembly and maintenance of new energy vehicles, the modular design of wiring harness systems is becoming a trend. Modular design can break down complex wiring harness systems into multiple modules, making installation and replacement easier. This not only improves production efficiency but also reduces maintenance costs. In modular design, the application of standardized interfaces is crucial. Using standardized connectors and interfaces can improve the universality and compatibility of wiring harness systems, reducing faults and maintenance issues caused by incompatible interfaces.

Modular and standardized designs not only enhance the flexibility of wiring harness systems but also increase their adaptability to different models and configurations. This design concept is significant in the manufacturing process and demonstrates great advantages in later maintenance and upgrades.

Intelligent Management

With the development of intelligent new energy vehicles, wiring harness systems also need to have intelligent management functions. By integrating intelligent monitoring and self-diagnostic functions into wiring harnesses, the current, voltage, and temperature of the harnesses can be monitored in real-time, preventing faults. For example, by monitoring the working status of the harnesses through sensors, once an abnormal situation is detected, the system can automatically alarm and take corresponding measures to avoid potential safety hazards.

Intelligent wiring harness management not only improves the safety and reliability of wiring harness systems but also simplifies maintenance work and reduces maintenance costs. Through intelligent management systems, the overall operational efficiency and safety of vehicles are significantly improved.


In conclusion, new energy vehicles pose many special requirements for Chinese automotive wiring harnesses, including high-voltage wiring harness design, lightweight requirements, data transmission wiring harnesses, heat dissipation and temperature resistance, modular design, and intelligent management. Each requirement involves complex technical challenges and innovative demands. Chinese automotive wiring harness companies need to continuously develop and apply new technologies to meet the development needs of new energy vehicles, promoting industry progress and enhancing market competitiveness.

How Does Konnra Meet the Complex Requirements of Automotive Wiring Harnesses through Technological Innovation and Optimized Design?

Konnra has always been at the forefront of this field, successfully meeting these complex requirements through technological innovation and optimized design. Our products not only adopt the latest high-voltage cable designs to ensure efficient and safe power transmission but also emphasize the application of lightweight materials, significantly reducing the weight of wiring harnesses and improving the range of new energy vehicles. Additionally, Konnra’s data transmission wiring harness designs are highly stable and fast, ensuring efficient communication between various electronic devices.

In terms of heat dissipation and temperature resistance, Konnra uses high-quality high-temperature-resistant materials, such as high-temperature nylon and polyether ether ketone (PEEK), to ensure the stability and safety of wiring harnesses in high-temperature environments. The application of modular design makes our wiring harness systems easier to install and maintain, and standardized interfaces improve system compatibility and flexibility. The integration of intelligent management functions, with real-time monitoring and self-diagnostic features, greatly enhances the safety and reliability of wiring harness systems.

If you are looking for high-performance wiring harness products that meet the special needs of new energy vehicles, Konnra is undoubtedly your best choice. Visit our website to learn more about our products, read user reviews, and recommendations. Choose Konnra to take your new energy vehicle to new heights in performance, safety, and sustainability. Shop now and let Konnra become an indispensable partner in your new energy vehicle project!

Share article