With the continuous improvement of consumers' requirements for charging speed, power performance, and endurance, the original 400V architecture is no longer able to meet higher power output demands. The voltage platform of new energy vehicles is evolving from 400V to 800V, 1000V, and even 1500V, and the charging current is soaring from 250A to 600A, 800A, and even 1000A. The corresponding main circuit harness continues to expand to over 95 mm ², 120 mm ², 240 mm ², and even 300 mm ², and the selection of high-voltage wire harness for new energy vehicles is also showing a differentiated trend:

l Passenger cars: The 800V platform can optimize the wire diameter by increasing the voltage (such as reducing the 85kW motor from 400V/35mm ² to 800V/25mm ²), but fast charging requirements (above 600A) still require a wire diameter of 95mm ² or more;  

l Commercial vehicles: High power (200kW+) and high temperature environment drive the wire diameter to 50-120mm ², and extreme scenarios on the 1500V platform require 240mm ² or more;  

l Energy storage system: The dynamic load and high temperature conditions require the wire diameter to match the peak current (such as 70 → 95mm ²), and a 1500V withstand voltage design is required.

In the future, material innovation and SiC technology may alleviate the pressure of wire diameter growth, but ultra-high power scenarios still rely on large cross-sectional area wire harnesses. Higher current levels impose stricter requirements on the conductivity, mechanical strength, and long-term reliability of the crimping area.

Traditional mechanical crimping: bottleneck has emerged, difficult to adapt to the trend of high voltage and high current

Traditional wire harness crimping technology relies on mechanical molds to apply pressure to metal terminals, pressing wires and terminals together. Although this technology has been applied for many years, its limitations have become increasingly apparent in high-voltage and high current applications of new energy.

1. Electrical performance degradation issue

The metal lattice damage caused by mechanical deformation leads to a significant increase in contact resistance under vibration/aging conditions, and is prone to local overheating hazards under high voltage and high current conditions. The destruction of coating integrity accelerates the electrochemical corrosion process, and the failure probability of new energy vehicles on the 800V high-voltage platform increases exponentially.

2. Limitations in process adaptability

The tolerance of crimping height must be strictly controlled within ± 0.05mm, as dimensional deviations caused by mold wear can directly lead to a cliff like drop in yield rate.

The physical crimping method has a cross-sectional ceiling, which is difficult to meet the manufacturing requirements of commercial vehicle 1000A high current wire harnesses.

Evolution of wire harness connection technology: Electromagnetic pulse crimping technology MPC

Traditional mechanical crimping technology, due to its inherent limitations, is no longer able to meet the manufacturing needs of high current, high reliability, and high efficiency. However, electromagnetic pulse crimping (MPC) technology, as a disruptive advanced manufacturing process, is sparking a silent revolution in the field of new energy wire harness manufacturing.

1. Electromagnetic pulse crimping technology: achieving efficient and high-quality connections with "transient high energy"

By applying transient high-energy current in the induction coil, a strong electromagnetic field is generated, which causes the metal terminal to rapidly contract and wrap around the wire core under the drive of electromagnetic force, achieving non-contact and thermally unaffected solid-state connection in just a few microseconds. The terminal and wire harness undergo "metallurgical bonding" - retaining the conductivity of the substrate while forming stronger interfacial atomic bonds than the substrate.

Core advantages of electromagnetic pulse wire harness crimping technology:

l Welding pressure composite has good compaction and zero porosity

l Non contact, does not damage the surface coating and workpiece

l Standardization of process control procedures and high product consistency

l Resistance as low as micro ohms, significantly exceeding industry standards

l The temperature rise is significantly reduced, and the tensile load is much higher than traditional crimping

l Green process, no auxiliary materials, zero emissions

With the development of the new energy industry towards high voltage and high power, traditional crimping technology has gradually shown its "ceiling". The electromagnetic pulse crimping technology, with its high efficiency, high quality, and high adaptability, is gradually becoming a new standard in the field of wire harness manufacturing.

The 800V high-voltage platform has begun to rapidly popularize, and the current density of the entire vehicle has significantly increased, placing higher demands on the load-bearing capacity and connection reliability of the wiring harness. Electromagnetic pulse crimping technology is the "weapon" to solve such key problems. Not limited to the new energy vehicle industry, electromagnetic pulse crimping technology has been widely used in the following fields:

l New energy vehicle high-voltage wiring harness and battery module connection, motor controller connection, charging system connection;

l Energy storage systems have a wide demand for high current connections, and electromagnetic pulse crimping can significantly improve connection stability

Under the dual drive of new energy and intelligent manufacturing, electromagnetic pulse crimping technology is moving from "black technology" to "mainstream manufacturing". It not only solves the pain points of traditional crimping, but also demonstrates irreplaceable advantages in key scenarios such as high-voltage platforms, high current wire harnesses, and dissimilar metal connections.