Car manufacturers OEM Solution

As powertrain systems shift toward hybrid and electrified architectures, wiring harnesses are exposed to higher temperatures, vibration loads, and current demands. Automakers increasingly face:

• Premature aging of engine-bay harnesses
• Terminal looseness under long-term vibration
• Inconsistent batch quality from outsourcing suppliers
• Electrical instability affecting vehicle performance and NVH

👔 Customer Requirements

A major automaker needed a redesigned engine-bay power harness for a new platform with:

• 125°C temperature resistance
• High-vibration endurance
• Low contact resistance and long-life terminals
• Full traceability and controlled process windows
• Rapid prototype development and process validation

Our Advantages

1️⃣ In-house engineering & simulation

• Terminal mechanical analysis and pull-force optimization
• Current-carrying and temperature-rise simulation
• Routing design and mounting layout
• Durability, vibration, and environmental testing

2️⃣ Full-process manufacturing capabilities

• Fully automatic cutting, stripping, and crimping
• 100% cross-section inspection (CCD + metallography)
• Comprehensive continuity and withstand-voltage testing
• In-house vibration, heat-shock, and corrosion testing labs

3️⃣ Strict quality management

• Standardized workshops with stable process control
• SPC-based batch monitoring
• Full PPAP, PFMEA, and Control Plan compliance

📄 Solution & Results

Jiusu optimized terminal geometry, redesigned the wire path, and introduced high-temperature sleeves backed by full reliability testing.
Outcome:

• 22% lower contact resistance
• Extended durability to 1500+ hours
• Significantly improved batch consistency
• Passed full DV/PV vehicle-level validation

📦️ Recommended Products

• ✔️High-temperature engine-bay power harnesses
• ✔️High-current terminal and anti-loosen structures
• ✔️Heat-resistant automotive wires
• ✔️Custom vibration-resistant wiring assemblies