The New Energy Vehicle (NEV) wiring harness assembly line is an automated system specifically designed for the production of wiring harnesses for new energy vehicles. It is widely utilized for the efficient and high-precision manufacturing of high-voltage, low-voltage, and high-speed data harnesses. This system bridges the final mile, guiding you from traditional "manufacturing" to intelligent "smart manufacturing."

However, in alignment with industry trends and the practices of leading enterprises, these production lines are rapidly evolving toward full automation, intelligence, and digitalization. This evolution aims to meet the rigorous demands of new energy vehicles for wiring harnesses characterized by exceptional safety and reliability.

Features of New Energy Vehicle Wiring Harness Production Lines**

High Automation:** Integrates processes such as automatic wire feeding, cutting, stripping, crimping, housing insertion, inspection, and sorting, achieving "lights-out factory" style unmanned operations.

Non-Destructive Laser Processing:** Utilizes laser technology to precisely cut the aluminum foil shielding layer of high-voltage wiring harnesses, avoiding damage to the internal braided mesh and boosting the yield rate to over 99.8%.

Full-Process Visual Inspection:** Equipped with over 20 CCD cameras to provide real-time monitoring of stripping dimensions, crimping deformation, terminal insertion depth, and other parameters, ensuring "zero-defect" shipments.

Industry 4.0 Integration:** Supports integration with MES systems to enable cloud-based production data traceability and predictive equipment maintenance, meeting the requirements of the IATF 16949 quality management standard.
Strong Customization Capabilities:** Capable of non-standardized design based on specific client production line layouts and product types (e.g., 800V high-voltage platforms), thereby supporting flexible manufacturing.

In automotive wiring harness production lines, the **terminal crimping** and **inspection** stages are the most critical, as they directly determine the electrical performance of the harness and the overall safety of the vehicle.

Terminal Crimping:** This stage involves securely connecting wires to connector terminals and is central to ensuring the stable transmission of signals and power. Poor crimping quality can lead to increased contact resistance, overheating, or even open circuits—consequences that are particularly severe in critical systems such as airbags and ABS. Crimping requires strict control over **crimping force, crimping height, and cross-sectional analysis**, as well as regular equipment calibration.

Inspection and Testing:** This encompasses **electrical performance testing** (continuity, insulation, dielectric strength) and visual/dimensional inspection**. Electrical testing ensures the absence of short circuits, open circuits, or poor contacts; visual inspection verifies terminal integrity (absence of deformation), proper seating of protective sheaths, and adherence to taping standards. Critical sub-harnesses—particularly those for airbags—require a **secondary electrical test** to prevent accidental deployment of contact springs.

Insulation Treatment and Wrapping:** Protective measures—such as heat-shrink tubing, corrugated tubing, or adhesive tape—are applied to the wiring harness to guard against abrasion, high temperatures, and moisture ingress. The wrapping method must be selected based on the risk level of the specific vehicle body location; for instance, areas in contact with sheet metal require full wrapping, while high-risk zones necessitate airtightness testing.

Raw Materials and Process Control:** The quality of copper busbars, terminals, and insulation materials directly impacts the service life and reliability of the wiring harness. Consequently, these components must undergo rigorous acceptance inspections and sample verific