EV wire harness production: the equipment list
High-voltage EV harnesses use 25–120 mm² shielded cable at 400–800 V — which means heavier stripping, shield processing steps and 100% electrical testing that conventional harness lines don't have. Here is what a real line needs, in process order.
| Step | Equipment | Why it's needed |
|---|---|---|
| 1. Cut & strip | Heavy-duty cut & strip machine | Measured cutting and jacket stripping of 25–120 mm² HV cable |
| 2. Shield processing | Braid brushing / folding station | Expose and fold back the shield braid for the shield connection |
| 3. Terminal crimping | Hexagonal / servo crimping machine | Gas-tight crimps on large HV terminals, ±0.02 mm height control |
| 4. Splicing | Ultrasonic metal welder | Solder-free copper joints for busbar and branch splices |
| 5. Sealing | Heat shrink processing machine | Adhesive-lined tubing over joints for IP sealing |
| 6. Testing | Hi-pot harness tester | 100% continuity + insulation + withstand voltage at 400–800 V systems |
EV harness equipment — common questions
What equipment does an EV high-voltage harness line need?
A typical HV harness cell needs: a heavy-duty cut and strip machine for 25–120 mm² cable, a shielded-cable processing station (jacket, braid, foil), a hexagonal crimping unit for HV terminals, ultrasonic welding for busbar and splice joints, heat-shrink processing with sealant tubing, and a hi-pot harness tester rated to 6 kV or higher.
How is EV harness processing different from conventional automotive harness?
Three differences: much larger cross-sections (25–120 mm² vs 0.35–6 mm²), shielded cable everywhere (requires braid-processing steps conventional lines do not have), and 100% hi-pot electrical testing because of 400–800 V system voltage.
What budget should a startup EV harness workshop plan for equipment?
A manual-assisted cell (semi-auto stripping + bench crimping + testing) starts around USD 15,000–30,000 in machines. A semi-automatic line for consistent volume typically runs USD 60,000–150,000. We quote exact configurations within 12 hours from your harness drawings.
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