Himinsen New Energy Vehicle Wiring Harness Automatic Processing Solution

Aug. 14, 2026

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As the core components for power transmission and signal control of new energy vehicles, high and low-voltage wiring harnesses directly determine vehicle driving safety in terms of connection reliability, insulation performance and EMC electromagnetic compatibility. Relying on self-developed core ultrasonic metal welding technology, Himinsen builds a full-process automatic intelligent processing system for wiring harnesses, effectively solving industry pain points such as non-standard shielding treatment, poor terminal connection with heat generation, manual assembly errors and untraceable quality of high-voltage harnesses.

Centered on D-series high-voltage terminal ultrasonic welding machines and X-series multi-strand wire harness welding machines, our complete solution is equipped with automatic wire cutting and stripping machines, integrated high-voltage shielding processing workstations, closed-loop servo crimping machines, CCD visual insertion inspection equipment and comprehensive harness performance testers. It covers all production procedures including precision wire cutting and stripping, automatic shielding net finishing, precise conductor welding and servo crimping, waterproof seal pre-installation, HVIL connector locking, as well as full insulation withstand voltage and IP air tightness testing, achieving an upstream automation rate of over 90%.

All production and testing data can be synchronously connected to the MES system, with each harness assigned a unique traceability code, fully complying with the IATF16949 automotive quality management system standards. We provide flexible cooperation modes including standalone equipment procurement, modular workstation construction and full turnkey automatic production lines. Widely applicable to mass production of battery pack main harnesses, motor three-phase harnesses, OBC connecting cables, AC/DC charging gun assemblies, as well as BMS and VCU low-voltage signal control harnesses, our solution helps wiring harness manufacturers improve production efficiency, reduce defect rates and comprehensively control production costs.

Four Core Advantages

1. Self-developed ultrasonic welding technology realizes copper-aluminum molecular fusion connection, featuring lower contact resistance, smaller temperature rise under high current and better long-term durability than traditional mechanical crimping;

2. Standardized automatic high-voltage shielding processing ensures excellent vehicle EMC anti-interference performance and avoids on-board electronic signal disorder;

3. Closed-loop multi-station visual quality inspection realizes full automatic testing of continuity, withstand voltage, grounding and air tightness, realizing automatic rejection of defective products;

4. Flexible modular design supports rapid model switching, adapting to both small-batch and mass flexible production of multi-model and multi-diameter wiring harnesses.