AutomotiveWiring

AutomotiveWiring refers to the network of electrical conductors used in motor vehicles to power and connect lights, sensors, actuators, and control modules. It includes copper wires, insulation, protective jackets, wiring harnesses, and connectors. Modern vehicles incorporate both 12‑volt circuits and high‑voltage systems in hybrids and electric vehicles.

Key elements are wiring harnesses that bundle wires, plus connectors, terminals, fuses, relays, grounds, and protective loom coverings. Conductors use copper with insulation materials such as PVC or XLPE, and jackets to resist heat and moisture. Data and control lines increasingly run over CAN, LIN, Ethernet, alongside power conductors.

Wiring is designed to minimize voltage drop, withstand vibration, and resist abrasion and moisture. Harness fabrication includes cutting, stripping, crimping, bundling into looms, inserting grommets, and securing routes with clips. Routes avoid hot surfaces and moving parts; testing covers continuity, insulation resistance, and, for high‑voltage systems, isolation checks.

Standards guide automotive wiring; ISO 6722 covers automotive cables, while ISO 26262 addresses functional safety. Industry practices also reference SAE connectors and environmental sealing. High‑voltage systems require strict insulation, isolation, and fault‑handling criteria.

Common issues include insulation wear, connector corrosion, and harness chafing from vibration, as well as moisture ingress. Regular inspection, proper sealing, and careful repair reduce failures. Ongoing trends emphasize modular harness designs and integration with vehicle networks and diagnostics.