vlg On-board wiring harness

　　I. Core Product Categories (Based on Vehicle System Functions)

　　VLG vehicle wiring harnesses are centered on "automotive-grade compliance + system-level adaptation," addressing the different needs of traditional fuel vehicles, new energy vehicles (EV/PHEV), and intelligent connected vehicles. They are divided into four main categories, covering four core systems: powertrain, cabin, intelligent driving, and high voltage:

　　1. Powertrain Vehicle Wiring Harness

　　Structural Features: Uses oil-resistant cross-linked polyethylene (XLPE) insulation (oil resistance grade conforms to ISO 6722-1 Class 3), conductors are multi-strand tinned copper wire (0.5-6mm²), some contain copper braided shielding (shielding effectiveness ≥60dB), supports waterproof connectors (IP6K9K, high-pressure water wash resistant);

　　Key Parameters: Temperature range -40℃~150℃ (suitable for high-temperature engine compartment environments), vibration resistance (10-2000Hz, acceleration 20G, conforms to ISO 16750-3), voltage drop ≤0.3V/m (rated current) 10-50A), insulation withstand voltage ≥1500V AC (no breakdown for 1 minute); Typical applications: engine control harness (connecting ECU and sensors), transmission harness (transmitting shift signals), fuel system harness (compatible with traditional fuel vehicles, resistant to fuel corrosion), and integrated with VLG's onboard 4G module to transmit engine operating data to the vehicle networking platform.

　　2. Cockpit Electronics Wiring Harness

　　Structural Features: Utilizes flexible TPE insulation (bending radius ≤ 5 times wire diameter, suitable for confined cockpit spaces), conductors are ultra-fine silver-plated copper wires (0.1-0.5mm²), integrating multiple circuits for "power + signal + data" (reducing wiring harness quantity by 30%), supports high-frequency connectors such as Mini-FAKRA and LVDS (transmission rate ≥ 3Gbps);

　　Key Parameters: Temperature range -40℃~125℃ (cabin environment), EMC electromagnetic compatibility (compliant with CISPR 25 Class 5), transmission delay ≤ 10ns (LVDS signal, suitable for central control screen display), insertion/removal life ≥ 1000 cycles (connector durability);

　　Typical Applications: Smart cockpit wiring harness (connecting central control screen, instrument panel, HUD, vehicle networking module), seat control wiring harness (electric seat adjustment, heating/ventilation signals), ambient lighting wiring harness (RGB lighting control signal transmission), and VLG in-vehicle WiFi 6. Antenna coordination ensures stable data transmission for the cabin entertainment system.

　　3. ADAS (Advanced Driver Assistance Systems) Vehicle Wiring Harness

　　Structural Features: Employs low-loss PTFE insulation (dielectric constant ≤2.1, reducing signal attenuation), conductor is multi-strand nickel-plated copper wire (0.3-1.0mm²), double-shielded structure (aluminum foil + tin-plated copper braid, shielding effectiveness ≥70dB), supports HSD (High-Speed Data) connectors (transmission rate ≥10Gbps, compatible with Ethernet);

　　Key Parameters: Temperature range -40℃~125℃, signal integrity (eye diagram test conforms to IEEE 802.3bw), vibration resistance (10-2000Hz, acceleration 15G), latency deviation ≤5ns (multi-sensor synchronization requirements);

　　Typical Applications: LiDAR harness (transmits point cloud data), camera harness (connects surround-view/forward-view cameras, 1080P/4K video signals), millimeter-wave radar harness (transmits distance/speed detection signals), in conjunction with VLG vehicle GNSS antennas and Trackers to achieve "sensor data +..." Location data is transmitted synchronously to ensure the accuracy of intelligent driving decisions.

　　4. High-Voltage On-Board Wiring Harness for New Energy Vehicles

　　Structural Features: Employs high-voltage EPDM/XLPE insulation (withstanding voltage 300V~1000V DC, suitable for EV/PHEV), conductor is multi-strand stranded bare copper (2.5-50mm², current carrying capacity 100-500A), includes a high-voltage shielding layer (copper braid + aluminum-plastic composite tape, protecting against electromagnetic radiation), supports HVIL (high-voltage interlock) function (ensuring safe insertion and removal);

　　Key Parameters: Temperature range -40℃~150℃ (high-temperature environment for battery packs and motor controllers), insulation resistance ≥100MΩ (500V DC), salt spray resistance (1000 hours, 5% NaCl, conforming to ISO 9227), flame retardant rating VW-1 (UL 94);

　　Typical Applications: Battery pack wiring harness (connecting cells and BMS battery management system), motor controller wiring harness (transmitting high-voltage power), charging system wiring harness (fast/slow charging interface to battery pack), and VLG... The vehicle-mounted high-voltage connectors work in tandem to ensure high-voltage safety and power transmission efficiency in new energy vehicles.

　　II. Core Technical Characteristics (Enhanced Automotive-Grade Capabilities)

　　1. Automotive-Grade Environmental Adaptability

　　Temperature and Weather Resistance: Customized insulation materials are used for different areas of the vehicle (engine compartment 150℃, passenger compartment 125℃, chassis -40℃). The materials pass high and low temperature cycling tests (-40℃~150℃, 100 cycles, performance degradation ≤5%), and are resistant to UV aging (compliant with ISO 4892-3, no cracking after 2000 hours of exposure).

　　Corrosion and Oil Resistance: The powertrain wiring harness insulation layer is resistant to engine oil and transmission oil (immersion for 500 hours, volume change ≤10%). The chassis wiring harness is resistant to mud, water, and salt spray (1000-hour salt spray test, conductor corrosion area ≤5%), complying with ISO 16750-4 environmental standards.

　　2. High Reliability and Safety Design

　　Shielding and Interference Resistance: Addressing the complex electromagnetic environment in vehicles (motor and inverter interference), a graded design of "single shielding (cabin) - double shielding (ADAS) - triple shielding (high voltage)" is adopted. The ADAS wiring harness shielding effectiveness is ≥70dB (100MHz-1GHz), preventing interference with high-precision sensor signals such as lidar and cameras.

　　Safety Protection: The new energy high-voltage wiring harness integrates HVIL high-voltage interlock (automatically cutting off high voltage upon disconnection), a temperature sensor (real-time monitoring of wiring harness temperature, alarming above 85℃), and connectors with anti-misplugging design (key-type structure to prevent reverse polarity connection), complying with ISO 6469-3 new energy vehicle safety standards.

　　Durability: Connector mating life ≥1000 cycles (cabin), ≥500 cycles (high voltage), wiring harness bending life ≥100,000 cycles (bending radius 10 times wire diameter), meeting the 15-year/200,000 km service life requirement of the entire vehicle.

　　3. Integration and Lightweighting

　　Multi-functional Integration: Utilizing a "functional integration" design, such as combining "cockpit wiring harness + vehicle networking wiring harness" (reducing harness length by 20%), and integrating "ADAS wiring harness + GNSS antenna wiring harness" (synchronously transmitting sensor and positioning data), reducing the overall vehicle wiring harness weight by 15-20% (compared to the weight of traditional distributed wiring harnesses);

　　Lightweight Materials: Conductors use high-conductivity copper alloy (conductivity ≥98% IACS), insulation layers use thin-walled TPE/XLPE (thickness reduced by 20% compared to traditional methods), and connectors use high-temperature resistant PA66 + glass fiber material (weight reduction of 10%), adapting to the lightweight requirements of new energy vehicles.

　　4. Integration with VLG Automotive Hardware

　　Integration with Communication Module: The cockpit wiring harness has a reserved interface for the VLG automotive 5G/NB-IoT module, with signal transmission loss ≤2dB (10-meter distance), ensuring stable transmission of vehicle network data (such as OTA upgrades and remote control) with latency ≤50ms;

　　Integration with Tracker: The chassis wiring harness connects to the VLG automotive tracker, transmitting vehicle vibration and position data. The vibration-resistant design ensures uninterrupted data acquisition under bumpy road conditions (data loss rate ≤0.1% at 20G vibration acceleration);

　　Adaptation to High-Voltage Components: The new energy high-voltage wiring harness is pre-integrated with the VLG automotive high-voltage connector (1000V DC withstand voltage), with standardized interfaces (compliant with GB/T 18487.1), requiring no additional adaptation and shortening the integration cycle to 1 week (traditional solutions require 2-3 weeks). III. Typical Application Scenarios (Combined with the Development Trends of Intelligent Vehicles)

　　1. Traditional Fuel Vehicle Scenario (Mid-range Family Cars)

　　Solution Combination: Powertrain wiring harness (oil-resistant XLPE material) + Cabin electronic wiring harness (flexible TPE) + VLG in-vehicle 4G module;

　　Application Logic: The powertrain wiring harness transmits engine ECU signals (such as fuel injection and ignition commands), while the cabin wiring harness connects to the central control unit and instrument panel. It works in conjunction with the 4G module to achieve collaborative processing of "vehicle status data (fuel consumption, RPM) + vehicle networking services (online navigation, music)," ensuring the basic intelligent needs of traditional fuel vehicles;

　　Key Achievements: Wiring harness failure rate ≤0.01%/year, EMC test pass rate 100% (compliant with CISPR 25 Class 3), suitable for mass production needs of vehicles with an annual output of over 100,000 units.

　　2. New Energy Vehicle Scenarios (EV/PHEV)

　　Solution Combination: High-voltage vehicle wiring harness (1000V DC withstand) + ADAS wiring harness (double-shielded) + VLG vehicle GNSS antenna + Tracker;

　　Application Logic: The high-voltage wiring harness connects the battery pack and motor controller, ensuring power transmission (voltage drop ≤0.2V/m at 300A current); the ADAS wiring harness transmits LiDAR and camera data (delay ≤5ns), working in conjunction with the GNSS antenna and Tracker to achieve integrated "intelligent driving perception + positioning + trajectory recording," meeting L2+ level assisted driving requirements;

　　Key Achievements: The high-voltage wiring harness has an insulation withstand voltage of 1500V AC without breakdown; the ADAS wiring harness achieves 100% signal integrity compliance; it is suitable for the range improvement needs of new energy vehicles (lightweight wiring harness reduces overall vehicle energy consumption by 5%). 3. Intelligent Connected Vehicle Scenario (Level 4 Autonomous Driving)

　　Solution Combination: ADAS Ethernet harness (10Gbps transmission rate) + Cockpit Ethernet harness (LVDS) + VLG automotive 5G millimeter-wave module + high-voltage harness;

　　Application Logic: The ADAS Ethernet harness connects multiple LiDARs and a high-performance domain controller (point cloud data transmission rate ≥10Gbps). The cockpit harness supports multi-screen interaction (central control + passenger entertainment screen, latency ≤10ns), and works in conjunction with the 5G module to achieve "V2X + remote driving" data transmission. The high-voltage harness ensures stable power supply to the domain controller and battery pack;

　　Key Achievements: The Ethernet harness EMC shielding effectiveness is ≥70dB, and the V2X data transmission latency is ≤20ms, meeting the requirements of Level 4 autonomous driving for "high bandwidth, low latency, and high reliability."

　　IV. Customized Services and Automotive-Grade Certification

　　1. Customized Process (Adapted to Automaker Development Cycles)

　　Requirements Survey: Define vehicle type (fuel/EV/intelligent driving), system requirements (powertrain/cabin/ADAS), environmental parameters (temperature, vibration, voltage level), and production scale (100,000-500,000 units per year);

　　Solution Design: 3D wiring simulation (based on CATIA software, optimizing wiring harness routing to avoid interference with other components), material selection (insulation layer, conductor, connector), shielding structure design (according to EMC requirements);

　　Sample Verification: Sample production completed in 2-3 weeks, testing items include: temperature cycling (-40℃~150℃), vibration (ISO 16750-3), EMC (CISPR 25), high voltage withstand (new energy vehicles), supporting vehicle-wide integration testing by automakers;

　　Mass Production Delivery: Adopting the IATF 16949 quality management system, mass production cycle of 4-6 weeks, providing an integrated kit of "wiring harness + connector + installation guide", supporting... 1. Just-In-Time (JIT) Delivery (adapting to automaker production line rhythms).

　　2. Automotive-Grade Compliance Certifications

　　International Certifications: IATF 16949 (Automotive Industry Quality Management System), UL 94 (Flame Retardancy Rating), ISO 6722 (Cables for Road Vehicles), ISO 16750 (Automotive Electronic Ambient Conditions);

　　Domestic Certifications: Compliant with GB/T 18487.1 (Conductive Charging Systems for Electric Vehicles), GB/T 25128 (Thin-Wall Insulated Wires for Automotive Use), CCC Mandatory Certification (Automotive Electrical Components);

　　Specific System Certifications: ADAS wiring harnesses comply with ISO 26262 Functional Safety (ASIL B-D level, based on intelligent driving level); high-voltage wiring harnesses comply with GB/T 31467.3 (Cables for High-Voltage Systems in Electric Vehicles). 3. Benchmark Cooperation Cases

　　Traditional Automakers: Providing powertrain and cabin wiring harnesses to a joint venture automaker, suitable for an annual production of 300,000 passenger cars, with a wiring harness failure rate of ≤0.008%/year, and passing CISPR 25 Class 4 EMC testing on the first attempt;

　　New Energy Vehicle Manufacturers: Providing high-voltage and ADAS wiring harnesses to a new energy vehicle company, suitable for L2+ level EV models, with high-voltage wiring harnesses withstanding 1000V DC, and ADAS wiring harnesses supporting 8-channel camera data transmission (3Gbps rate), with over 100,000 units delivered in batches;

　　Intelligent Connected Vehicle Manufacturers: Providing Ethernet ADAS wiring harnesses to an L4 level autonomous driving company, with a transmission rate of 10Gbps, signal latency ≤5ns, suitable for the collaborative needs of multiple LiDARs and high-computing-power domain controllers, ensuring the accuracy of autonomous driving decisions.

　　IV. Selection Recommendations (Based on Vehicle Model and System Matching)

　　Traditional Gasoline Vehicles (Mid-range Family Vehicles)

　　Recommended Type: Powertrain Wiring Harness (VLG-OBWH-Power-1) + Cockpit Electronic Wiring Harness (VLG-OBWH-Cockpit-1)

　　Key Parameters: Temperature Resistance -40℃~150℃ (Powertrain) / -40℃~125℃ (Cockpit), Vibration Resistance 10-2000Hz (15G), EMC Compliant with CISPR 25 Class 3

　　Compatible Product Combination: VLG Automotive 4G Module + Standard Automotive Antenna, meeting basic power control and vehicle networking requirements.

　　New Energy Vehicles (EV/PHEV, L2+ Level)

　　Recommended Type: High-voltage vehicle wiring harness (VLG-OBWH-HV-1, withstands 1000V DC) + ADAS wiring harness (VLG-OBWH-ADAS-1, double shielded)

　　Core Parameters: Current carrying capacity 100-500A (high voltage), signal transmission rate ≥3Gbps (ADAS), HVIL high-voltage interlock function, ISO 26262 ASIL B level

　　Compatible Product Combination: VLG vehicle GNSS antenna + Tracker + high-voltage connector, ensuring power safety and intelligent driving data transmission.

　　Intelligent Connected Vehicles (L4 Level Autonomous Driving)

　　Recommended Type: ADAS Ethernet ...H-ADAS-Eth-1 (10Gbps) + Cockpit Ethernet Harness (VLG-OBWH-Cockpit-Eth-1) + High-Voltage Harness (VLG-OBWH-HV-2)

　　Key Parameters: Signal delay ≤5ns (ADAS), EMC shielding effectiveness ≥70dB, ISO 26262 ASIL D grade, temperature resistance -40℃~150℃

　　Compatible Product Combination: VLG automotive 5G millimeter-wave module + high-performance domain controller harness + multi-sensor connectors, meeting the needs of vehicle-to-everything (V2X) and fully autonomous driving.

　　Commercial Vehicles (Trucks, Buses)

　　Recommended Type: Heavy-duty Power Harness (VLG-OBWH-Power-Truck-1, Conductor 6-50mm²) + Chassis Harness (VLG-OBWH-Chassis-1, IP6K9K)

　　Key Parameters: Current Carrying Capacity 50-200A, Vibration Resistance 10-2000Hz (20G), Salt Spray Resistance 1000 Hours, Suitable for Heavy-Duty Commercial Vehicles and Harsh Road Conditions

　　Compatible Product Combination: VLG Automotive NB-IoT Module + Track