New Energy Vehicle High-Voltage Wire Harness Industry

Demand Analysis

High-voltage wire harness welding often suffers from insufficient joint strength. Traditional crimping or fusion welding processes are inefficient and may cause environmental contamination. Multiple processing steps are scattered across different stages, making system integration difficult. These limitations make it challenging to meet automotive-grade mass production requirements and prevent production data traceability.

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New Energy Vehicle High-Voltage Wire Harness Industry

Solution for High-Voitage Wiring of New Energy Vehicles

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Core Customer Pain Points

High-voltage platform wiring harnesses face four major issues in process, EMC, durability and supply chain, bringing hidden safety and after-sales risks.

Transmission Process

High voltage & large current cause severe heat generation; traditional crimping suffers high rates of cold solder joints and detachment.

EM Interference

Severe electromagnetic interference on 800V platforms leads to easy shielding failure.

Working Condition Durability

Harness reliability degrades drastically under temperature cycling and vehicle vibration.

Supply Chain Matching

Inconsistent manufacturing standards across multiple suppliers result in poor compatibility and prominent hidden risks.

Customized Landing Solution

Core Idea

Process Innovation

We apply high-precision terminal crimping and ultrasonic welding technologies to substitute conventional tin soldering and riveting. The solution delivers spark-free, low-resistance and highly consistent high-voltage connections to fulfill high-current and high-safety standards.

Automation Integration

Multiple working procedures including wire cutting, stripping, crimping, welding and testing are integrated into flexible automated production lines, drastically cutting manual intervention while improving production efficiency and product consistency.

Digital Management & Control

Data collection is interconnected with the MES system to realize full production traceability, real-time quality monitoring and continuous process optimization, in compliance with IATF 16949 and other automotive quality management standards.

Customized Adaptation

Exclusive combined solutions for processes and equipment are customized for various vehicle types (passenger & commercial vehicles) and application scenarios (powertrain & charging systems).

Project Implementation Process

We provide one-stop full-cycle services covering demand communication, custom modeling, precision machining, reliability testing, prototype verification, trial & mass production delivery, as well as lifelong after-sales operation and maintenance for customized NEV harness automation equipment.

Demand Communication

In-depth sorting out production pain points such as harness output, specifications and cycle time to clarify core customization demands.

Custom Scheme & Modeling

Build 3D digital models via process simulation platforms and deliver exclusive automation solutions for NEV wiring harnesses.

Precision Manufacturing & Machining

Independently process core ultrasonic modules and mechanical parts, with standardized modular assembly for high precision.

Multi-Dimensional Reliability Testing

Conduct full-performance tests covering electricity, welding and durability per ISO9001 four-level inspection standards.

Prototype Debugging & Verification

Repeatedly debug welding parameters simulating client on-site conditions for full machine performance verification.

Small-Batch Trial Production

Support customers with trial welding of harness samples to optimize process parameters and eliminate mass production risks in advance.

Mass Production & Delivery

Graded lead time guarantee enables fast delivery via modular production, supported by sufficient spare parts stock.

Full-Lifecycle After-Sales Operation & Maintenance

7×24 remote diagnosis and on-site maintenance, with lifelong free optimization of harness welding processes.

Results Display

Solution for High-Voitage Wiring of New Energy Vehicles

Welding efficiency increased by more than 50%, product yield rate stabilized at 99.9%, and production costs reduced by 30%; fully compliant with IATF 16949 automotive-grade standards, enabling full-process production data traceability, and perfectly matching the stringent quality and efficiency requirements of BYD high-voltage platforms.

Project Core Advantages

Relying on over 20 years of technical accumulation in industrial ultrasonic technology, Himinsen has built an integrated innovation platform driven by digitization and intelligence, and formed an interdisciplinary R&D team covering acoustics, precision machinery, servo electronic control, vision inspection and industrial software, realizing independent control of core algorithms, hardware and complete solutions.

R&D Structure

We run an ultrasonic harness welding R&D division and joint lab with NPU. Simulation platforms support NEV harness technology & custom automation solutions.

Certifications & Patents

National high-tech enterprise with ISO9001 & patents. Our self-developed equipment gains industry awards and global mass application.

Global Collaboration

We follow international standards, introduce overseas ultrasonic algorithms and co-develop world-class 800V high-voltage welding equipment with industry leaders.

Self-developed Core Parts

Full in-house production of ultrasonic generators, welding heads and boosters. Our equipment delivers top precision for all customized NEV harness lines.

Customer Testimonials

Mr Johnson

Head of Wiring Harness Division

Himinsen ultrasonic welding equipment is stable and reliable. Combined with Haiseng’s fully automatic processing line, it not only solves the core pain points of welding strength and production efficiency for our high-voltage wire harnesses, but also achieves process integration and data traceability. It fully meets the requirements of automotive-grade mass production and is a strategic partner we trust.

Mr Oliver

Head of Intelligent Manufacturing & Technology Center

The combined solution of Himinsen and Haiseng is perfectly tailored to our multi-variety and small-batch production model. Rapid model changeover and automated integration have greatly boosted production efficiency. Meanwhile, its welding precision and stability fully meet the stringent requirements of industrial control equipment, achieving the dual goals of cost reduction and efficiency improvement.

Mr Liam

Director of Charging Gun R&D

The one-stop wiring harness processing solution jointly provided by HIimisen and Haiseng effectively addresses the core pain points of liquid-cooled ultra-fast charging guns regarding high-current transmission, fatigue resistance and production efficiency. With stable and reliable equipment and a high certification pass rate, you have been a key partner supporting the mass production and launch of our liquid-cooled ultra-fast charging guns.

Mrs Chloe

New Energy Technology Director

Safety and long service life are core competitiveness of energy storage systems. The integrated solution from Himinsen and Haiseng effectively addresses the pain points of high-current transmission, stability and service life of our high-voltage wiring harnesses. Featuring high automation and full data traceability, it delivers robust safety assurance for our energy storage products.

Mr Elijah

Senior R&D Engineer

The aerospace industry sets extremely stringent requirements for product reliability. Himinsen's precision welding technology and Haiseng's precision crimping process fully align with our core demands. Its outstanding lightweight design and superior reliability have exceeded our expectations, delivering solid technical support for our aerospace-grade products.

Miss Evelyn

Quality Director, Medical Device Manufacturer

Safety is the top priority for medical device manufacturing. Himinsen's medical-grade ultrasonic welding equipment fully complies with medical cleanliness standards and precision welding specifications. It also ensures ultra-reliable wiring harness connections and has obtained relevant medical certifications, making us your preferred supplier for medical device harness processing.

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New Energy Vehicle High-Voltage Wire Harness Industry

New Energy Vehicle High-Voltage Wire Harness Industry