Dual drive of automotive electronics and photovoltaic energy storage, device intelligence becoming mainstream

In recent years, under the wave of intelligent transformation in the global manufacturing industry, industrial control wiring harnesses, as the core component of the “nervous system” of equipment, are facing unprecedented development opportunities. In 2025, driven by the strong development of automotive electronics and photovoltaic energy storage, the industrial control wiring harness market will show explosive growth, and the popularization of intelligent production equipment will become a key driving force for industry upgrading.
The acceleration of automotive electronicization has injected strong momentum into the industrial control wiring harness market. With the penetration rate of new energy vehicles breaking through the 40% mark, the electronic and electrical architecture of the entire vehicle is undergoing revolutionary changes. The popularization of domain controller architecture has led to the transformation of vehicle internal wiring harness systems from traditional distributed cabling to centralized topology, which not only significantly increases the usage of single vehicle wiring harnesses, but also puts higher demands on the transmission performance of wiring harnesses. Taking a leading new energy vehicle manufacturer as an example, the total length of its latest model’s wiring harness has reached an astonishing 3500 meters, which is nearly 50% longer than traditional fuel vehicles. At the same time, the rapid iteration of autonomous driving technology has driven a geometric growth in the number of onboard sensors, and the widespread application of new sensing devices such as millimeter wave radar and laser radar has given rise to a strong demand for high-frequency and high-speed transmission wiring harnesses. Industry experts predict that by the end of 2025, the global market size of automotive electronic wiring harnesses is expected to exceed 80 billion yuan, with a compound annual growth rate of over 15%.

The booming development of the photovoltaic energy storage industry has become another major growth engine in the industrial control wiring harness market. Driven by the “dual carbon” target, China’s newly installed photovoltaic capacity has maintained a growth rate of over 20% for three consecutive years, with large-scale ground power stations and distributed photovoltaic projects advancing simultaneously. The photovoltaic power generation system, from components to inverters, from combiner boxes to energy storage devices, relies on the connection of high-quality industrial control wiring harnesses at every stage. Especially in the field of series inverters, with the 1500V system becoming the mainstream of the industry, the demand for high-voltage resistant and anti-aging harnesses is growing explosively. The energy storage system also brings new opportunities to the wiring harness industry. The implementation of high-voltage connections between battery modules, temperature monitoring, and other functions requires dedicated wiring harnesses as carriers. According to industry research data, the global market size for photovoltaic energy storage dedicated wiring harnesses is expected to reach 12 billion yuan by 2025, with China accounting for over 35% of the market share.
The wave of device intelligence is reshaping the production methods and product forms of industrial control wiring harnesses. The traditional manual wiring method is gradually being replaced by automated production lines, and the popularization of advanced equipment such as intelligent wire cutting machines and fully automatic terminal crimping equipment has improved the processing accuracy of wire harnesses to the ± 0.1mm level. A case study of an intelligent factory invested and constructed by a well-known wire harness manufacturer shows that by introducing MES system and industrial robots, its production efficiency has been improved by 40%, and the defect rate has been reduced to below 0.5%. At the product level, the trend towards intelligence is driving the development of wire harnesses towards “lightweight, modular, and integrated” direction. The technological breakthrough of replacing copper wires with aluminum wires has reduced the weight of wire harnesses by 30%, and composite wire harnesses that integrate power, signal, and data transmission functions are becoming the preferred choice for high-end equipment. More noteworthy is the emergence of intelligent wiring harnesses with self diagnostic functions. These products are equipped with miniature sensors that can monitor temperature, vibration, and other parameters in real-time, providing data support for predictive maintenance.

Material innovation and process upgrading have become the new focus of industry competition. Under harsh working conditions such as high temperature, high humidity, and strong electromagnetic interference, traditional wire harness materials are no longer able to meet the demand. The new type of polyetheretherketone (PEEK) insulation material has been widely used in new energy vehicle motor winding harnesses due to its excellent temperature resistance (continuous use temperature can reach 250 ℃). The popularization of silver plated copper wire has solved the skin effect problem in high-frequency signal transmission, increasing data transmission rates to over 10Gbps. Breakthroughs have also been made in connector technology, with sealed connectors with a waterproof rating of IP68 allowing industrial control wiring harnesses to operate stably even in harsh outdoor environments. In terms of technology, the maturity of laser wire stripping technology makes it possible to process fine wire diameters (below 0.1mm ²), providing a reliable connection solution for miniaturized equipment.