New Energy Vehicle High-voltage Wiring Industry

Solutions

New Energy Vehicle High-voltage Wiring Industry New Energy Vehicle Low-voltage Wiring Industry Charging Gun and Charging Station Industry AI Server Wiring Harness Industry Energy Storage & PV Connector Industry Industrial Electronic Wiring Industry Aerospace Wiring Industry Medical Equipment Wiring Harness

Home Solutions

New Energy Vehicle
high-voltage Wiring Industry

Scheme Background

Industry Pain Point

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.

For new energy passenger and commercial vehicles equipped with 400V/800V high-voltage platforms and under high-power fast-charging operating conditions, we rely on our core capabilities in R&D and manufacturing of high-voltage wiring harnesses as well as precision ultrasonic welding to deliver integrated high-voltage connection solutions for complete vehicles. These solutions address core technical challenges of automotive-grade high-voltage connections and ensure safe and stable operation of vehicle-wide high-voltage systems.

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).

Implementation Path

We deliver a full closed-loop service from scheme design to lifelong after-sales technical support, covering six core links

Scheme Design

Customize and model harness solutions matching vehicle high-voltage architecture

Precision Manufacturing

Process products with self-developed welding technology

Reliability Testing

Conduct multi-dimensional temperature, vibration and voltage resistance tests

Vehicle Matching

Complete whole vehicle adaptation & debugging

Mass Delivery

Launch batch production and shipment

After-sales Service

Provide full-lifecycle technical follow-up support

Solution Effect

High-voltage connection failures are reduced by more than 40%, eliminating problems such as poor soldering, overheating, and leakage; the wiring harness can withstand a wide temperature range of -40℃ to 200℃, greatly improving the stability of the vehicle operation; the solution has a first-time adaptation success rate of over 95%, shortening the customer's project verification cycle by 30% and significantly reducing the after-sales claim rate.

Successful Cases

25mm² copper wire welding application

Ultrasonic welding solution for 25mm² copper wires, delivering low-resistance, high-strength joints.

Learn more

95mm² aluminum wire welding application

High-voltage wire harness welding often suffers from insufficient joint strength. Traditional crimping or fusion welding processes are inefficient and may cause environmental contamination.

Learn more