Electrical Performance Testing and Analysis of Aluminum Wire Harness for Electric Vehicle under Different Environments

With the development of electrification and intelligence in vehicles, smart devices are extensively used in automobiles, making the electrical wiring increasingly complex. This increases the overall vehicle cost and energy consumption, thus highlighting the importance of cost control and lightweighting of automotive cables. Among them, aluminum wire harness are gaining attention due to their light weight and low cost. This paper verifies the feasibility of using ultrasonic welded aluminum wire harness and copper terminals in electric vehicles by analyzing and comparing the differences in pull-out force, contact resistance, and corrosion resistance under different terminal and harness connecting methods. The study provides a reliable basis for cable lightweighting.