The wiring system is a complex assembly consisting of multiple wire harnesses connecting all electrical/electronic components in the vehicle. The wiring system transmits power and signals between actuators, sensors and ECUs. Due to the level of customization in today’s vehicles, modern wiring systems are designed to support an infinite number of configurations.
In addition, as automakers continue to add more and more advanced new vehicle features, so does the complexity of wiring systems. A typical wiring system may contain 10,000 individual part numbers. Manufacturers must consider all possible vehicle configurations, which may consist of millions of combinations. While manufacturing these complex systems, companies must meet tight deadlines, adhere to stringent quality requirements, and minimize the cost and weight of the wiring harness.