1. Electrical Performance
High Conductivity:
Copper and aluminum are the most common conductors in wiring harnesses, with copper being the preferred material due to its superior electrical conductivity. In high-current applications, such as automotive engine starting systems or electric vehicle power distribution, wires with high conductivity minimize resistance and reduce energy loss. This ensures quick response and efficient power delivery—critical for performance and fuel economy.
Reliable Insulation:
The insulation layer in wiring harnesses prevents short circuits and leakage, especially in compact or multi-layered harness structures. Materials like PVC, XLPE, or silicone rubber are widely used, depending on the application. For instance, in infotainment systems or ADAS (Advanced Driver Assistance Systems), excellent insulation not only protects circuits but also reduces electromagnetic interference (EMI), maintaining signal integrity for accurate data transmission.
2. Physical Properties
Flexibility for Tight Spaces:
Wiring harnesses are often routed through tight, curved, or moving parts—such as car doors, tailgates, robotic arms, and HVAC systems. In these cases, wire flexibility is crucial. Stranded copper wires, especially those with fine-stranded construction, offer enhanced flexibility, making them ideal for dynamic environments. Good flexibility reduces the risk of wire breakage due to continuous bending, ensuring long-term reliability of the harness.
Mechanical Strength in Harsh Conditions:
In industrial and aerospace wiring harnesses, wires must withstand mechanical stress, vibration, and tension. Enhanced strength can be achieved through reinforced core designs or the use of durable conductor alloys. For example, in aircraft engines or off-road machinery, harnesses are exposed to strong vibration and temperature changes. Using high-strength wires ensures mechanical integrity and continuous system operation without failure.
3. Environmental Adaptability
Temperature Resistance:
Temperature extremes are common in the wiring harness industry. Engine compartments can exceed 100°C, while some outdoor or aerospace applications face sub-zero conditions. Wires insulated with high-temperature materials like silicone rubber or fluoropolymer maintain performance even in extreme heat, while cold-resistant insulation ensures flexibility and durability in freezing environments.
Corrosion Resistance:
In marine, chemical, or underbody automotive applications, moisture and chemicals pose a serious threat to wires. Tinned copper conductors and specialized anti-corrosion insulation coatings are commonly used in these harnesses to prevent oxidation and chemical degradation. This ensures the wiring harness remains functional and safe over years of exposure to harsh surroundings.
Final Thoughts
In the wiring harness industry, wires are more than just carriers of electricity—they are engineered components designed for performance, safety, and longevity. From ensuring your car starts reliably every morning to supporting vital aerospace systems, the right choice of wire based on its electrical, physical, and environmental characteristics is essential to the overall success of the harness and the system it powers.