Case Study: High-Voltage EV Charging
Wire Harness Assembly
Read our case study on manufacturing a zero-defect high-voltage EV charging wire harness. See how Cablum helped a global OEM achieve IP67 sealing and 360° EMI shielding under an aggressive 8-week SOP timeline.
Key Outcomes
The Challenge
A Tier 1 supplier of EV charging systems required a high-voltage harness that could withstand extreme temperatures (-40°C to 105°C) and provide superior EMI shielding to prevent interference with sensitive vehicle electronics.
The project was further complicated by an aggressive, time-sensitive product launch schedule and the absolute requirement for production under strict IATF 16949 standards.
Our Engineering Solution
Our engineering team collaborated directly with the client's design engineers to propose a comprehensive solution:
Material Selection
Selected specialized XLPE wires & TE Connectors for high-temp resistance and a TPU overmold for durability.
Double Shielding
Engineered a double-layered shielding design (Al-foil + tinned copper braid) to provide 360° EMI protection.
The Results
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Zero Defects Validation:
Passed 3000-hour thermal shock & vibration testing with zero failures.
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On-Time Launch:
Met the critical Start of Production (SOP) deadline despite tight timelines.
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IATF Compliance:
Full PPAP Level 3 documentation provided and approved on the first submission.
Case Study Q&A
Project Snapshot
- Industry: Automotive EV
- Application: HV Charging
- Voltage: 800V System
- Standard: IATF 16949