The Wiring Harness Industry Embraces a Technological Revolution: Intelligent Monitoring and Green Manufacturing Lead the New Wave
2025,07,31
Wuhan International Expo Center will host the industry grand event — the 2025 Wuhan Connector, Cable, Wire Harness, and Processing Equipment Exhibition this October. This exhibition will not only gather global industry elites but also showcase the latest breakthroughs in the wire harness industry within the realms of intelligence, automation, and green manufacturing. From smart monitoring wire harnesses to fully automatic crimping technology, a quiet technological transformation is reshaping this traditional industry. 01 Intelligent Monitoring Technology, Real-time Protection for Wire Harness Safety
A recently disclosed patent technology demonstrates an innovative direction in the industry—integrating arrays of temperature sensors and humidity sensors within the insulation layers of multiple wires.
This innovative design can monitor real-time changes in temperature and humidity around the wires, promptly detecting potential issues such as insulation layer aging, short circuits, and other problems caused by excessive temperature or high humidity.
The male connector integrates a current sensing module, while the female connector integrates a voltage sensing module, forming a comprehensive, multi-parameter safety monitoring network. This intelligent wire harness represents a significant shift in the industry from passive protection to proactive monitoring.
02Innovation in Production Processes Solves Industry Pain Points
In the critical stages of wire harness production, patent innovations are continuously emerging. A newly authorized automotive wire harness terminal crimping technology has addressed a long-standing technical challenge in the industry: the deformation of terminal tapes under traction forces. This technology dynamically adjusts the operating parameters of the traction and winding components during the terminal crimping process, achieving precise crimping control based on changes in the base tape tension. This breakthrough significantly enhances the consistency and reliability of automotive wire harness terminal crimping.
Additionally, an innovative winding device has solved the issue of tension control during the wire harness collection process. The device uses pressing pressure to automatically adjust its height, ensuring that the wire harness maintains a stable tension throughout the collection process, thereby greatly improving production quality.
03Cultivating Skilled Talent to Strengthen Industrial FoundationsAs industries undergo technological upgrades, the development of a highly skilled workforce becomes a critical support for industry growth. Recently, the Jizhou District "Tiangong Cup" Automotive Wiring Harness Assembly Skills Competition attracted more than 40 industrial workers from across the district to compete. The competition featured six events, including wiring harness assembly, press tool assembly, and fixture assembly. Competitors were required to complete a series of tasks, such as cutting, stripping, crimping, and assembling wiring harnesses, within a specified time.At a training base in Shandong, faulty wiring harnesses have been turned into "living textbooks." Technicians, along with young instructors, work together to strip wires, measure, and explain, not only repairing numerous pieces of equipment but also delivering over 200 hours of on-site instruction. This approach has achieved a comprehensive benefit of "repair one, teach many, save a batch."
