Development trend of new energy vehicle wiring harness

We know that low-voltage wiring harnesses are labor-intensive, 70% are produced manually, are tightly bound to OEMs, and the regional differentiation is obvious. New energy passenger vehicle wiring harnesses are worth about 5,000 yuan, of which high-voltage wiring harnesses are about 2,500 yuan, and high-voltage cables and high-voltage connectors account for nearly half of the value respectively. It is a purely incremental market that grows with the growth of new energy vehicles, with more than 10 billion new markets and rapid growth.

The low-voltage wiring harness of new energy vehicles is not much different from traditional vehicles. The disappearance of the engine reduces the engine wiring harness. The main differences are the high-voltage wiring harness, the emergence of power batteries, the application of electric motor drive, and other parts such as car chargers and compressors Electronic applications have brought with it a new wiring harness system on a 600 volt high voltage architecture.

According to the different high-voltage architectures of new energy vehicles, there are generally about 8 high-voltage wiring harnesses:

• DC charging socket --- power battery
• AC charging socket --- car charger
• Car charger --- high voltage distribution box
• High-voltage distribution box --- power battery
• High-voltage distribution box --- motor
• Car charger --- electric compressor
• Car charger --- PTC heater
• High-voltage wiring harness in power battery pack

  Compared with low-voltage wiring harness, high-voltage wiring harness has many parts and relatively low complexity. It mainly includes high-voltage cables and high-voltage connectors, as well as auxiliary fixing and protection components. China's automotive wiring harness market has reached a scale of 100 billion yuan, and the global scale exceeds 300 billion yuan.

  Comparison of high voltage crosslinked XLPE and silicone cable

  

  XLPE or silicone rubber cables are mainly used for high-voltage cables in vehicles. High-voltage cable bicycles account for about half of the high-voltage wiring harness, 800 yuan (cross-linked cable)-1,000 yuan (silicone rubber cable). XLPE is a low cost for domestic manufacturers and good performance for silicone wires from foreign manufacturers

  • As high-voltage cables for automobiles have only just begun, domestic manufacturers are still at the stage of learning from foreign manufacturers. The current consumption is still small and the price is high. After large-scale production in the later period, prices and costs will return.
  • As the XLPE process is more mature, manufacturers can add crosslinked mother particles for direct production, and the cost and construction period are relatively low. At present, domestic car manufacturers mainly choose to use XLPE. The mainstream manufacturers include Xinhongye, Hengtong Optoelectronics, Baoxing Cable, Ogilvy, Cobb Optoelectronics
  • The high temperature resistance (-50 ° C--180 ° C) and flexibility of silicone rubber cables are very helpful for wiring inside the car. Foreign manufacturers mainly choose silicone rubber cables, such as Klopp, Leoni, Live electricity, Kroschu. Domestic manufacturers are also trying to develop silicone rubber cables. The main difficulty lies in the optimization of the synthetic ratio of silicone rubber materials and the optimization of technology. At present, foreign-funded enterprises do not have a silicone wire production line in China, and the products are still imported. Domestic companies started with Xinhongye. , Hengtong, Huacheng, Kabei billion. Development trend of new energy vehicle wiring harness

    1 Low-voltage wiring harness improves automation level and increases gross profit margin

    The characteristics of low-voltage automotive wiring harness models are quite different. 70% artificial production leads to lower gross profit margins and production efficiency. The future development direction is to seek standardized parts in customization, as well as cable pretreatment and pre-assembly. Process, continuously improve the level of automation, improve efficiency and gross profit margin.

    In the industry, just like Lenny, the final assembly line has tried to improve the efficiency of the station and the board at the same time. Second, such as Kunshan Huguang, it has made good progress in trying to automate production in the areas of incoming materials storage, parts out of the warehouse, and small line pre-assembly.

    2 Large-scale high-voltage wiring harness concentrated and lightweighted to the wiring harness plant

    At present, there are many manufacturers of high-voltage wire harnesses. Wire harness factories and component manufacturers are involved in small-batch production. The future development direction is the trend of concentration to the wire harness factory after the effect of scale, which improves the gross profit and quality of products.

    The weight reduction of wire harnesses is also a direction that major car manufacturers are currently trying. The main weight of wire harnesses lies in the copper material of the cables. How to properly select cable applications and the application of aluminum conductors is one of the topics for future lightweighting.

    3 Systematic development of high-voltage connectors improves competitiveness

    Foreign manufacturers only have Tyco Electronics high-voltage connector research and development investment early, the product has become a system, but localization is still in progress, the price is more expensive; domestic manufacturers in the early development of new energy vehicles using high-voltage high-current connectors from other industries for automotive, Quickly seized the market and seized the first opportunity. The next step is to gradually make a complete product series of high-voltage connectors for new energy vehicles, from small currents to high currents, from single-pin to multi-pin, right-angle to 90-degree connections. Various product lines have been completed, on the one hand, to enhance their own competitiveness, and on the other hand, to strengthen the binding relationship with OEMs.

    4 Development of high-voltage silicone rubber cables makes up for technical and productivity gaps

    High-voltage silicone rubber cables are the development direction of new energy vehicles. On the one hand, due to the convenience of car body wiring, and on the other hand, due to high-temperature safety performance, foreign manufacturers currently have no production lines in China, and automotive silicone wires are imported. The delivery time is long and the price is expensive. Domestic manufacturers are stepping up development to make up for the gaps in technology and capacity. Foreign manufacturers are also making localization actions, and subsequent competition will be more intense.