What Types of Automotive Cable Assemblies do We Offer

Definition:Automotive cable assemblies are specialized wiring systems designed for use in vehicles and other automotive applications. These assemblies connect and transmit electrical signals or power between various components and systems, ensuring the efficient operation of functions such as lighting, engine performance, infotainment, and safety features. Their design prioritizes durability, reliability, and resistance to harsh environmental conditions typical in automotive environments, such as vibration, temperature extremes, moisture, and chemical exposure.

Types of Connectors

Electrical-Aircraft-Air-Aviation-Plug-Connectors

Automotive-Adapter-Ignition-Coil-Connectors

Audio and Video Cable Assemblies

Producing automotive cable assemblies involves challenges like ensuring durability in extreme environments and achieving precise customization for integration with complex vehicle systems.

By understanding these challenges, we can leverage cable solutions to improve the efficiency, reliability, and cost-effectiveness of your products.

Automotive Cable Assemblies

Power Distribution Cable Assemblies

Power distribution cable assemblies in the automotive industry are critical components designed to manage and distribute electrical power from a vehicle’s main power source (typically the battery) to various subsystems and components throughout the vehicle. These cable assemblies ensure the safe and efficient operation of the vehicle's electrical and electronic systems.

Battery Connections: High-current cables connecting the battery to the starter motor and alternator for power generation and distribution.
Fuse and Relay Boxes: Distributing power from the battery to various circuits via fuse and relay boxes to prevent overload and protect components.
Main Wiring Harness: Primary harnesses connecting key power-dependent subsystems, such as lighting, engine control units (ECUs), and HVAC systems.
Charging Systems: Connecting alternators or charging units in electric and hybrid vehicles to battery management systems (BMS).
High-Voltage Systems (for EVs) High-voltage cables distribute power from lithium-ion batteries to electric drivetrains and inverters.

Automotive Cable Assemblies

Engine & Transmission Cable Assemblies

Engine & Transmission cable assemblies are specialized wiring solutions designed to connect and support the electrical systems within a vehicle's engine and transmission. These assemblies facilitate the communication and power supply needed for the operation, monitoring, and control of these critical systems. As vehicles become increasingly reliant on electronics for efficiency and performance, these cable assemblies play an indispensable role in ensuring reliable functionality.

Heat Resistance:Designed to withstand high temperatures generated by the engine and exhaust systems, typically using materials like silicone, XLPE (cross-linked polyethylene), or ETFE (ethylene tetrafluoroethylene) for insulation.
Vibration and Flexibility:Built to endure constant movement and vibrations from the engine and drivetrain without compromising performance, incorporating strain relief designs and flexible insulation materials.
Chemical and Oil Resistance:Engineered with protective coatings to resist exposure to automotive fluids such as oil, grease, and coolant.
Durability:Uses robust materials like braided shields, corrugated tubing, or conduit protection to prevent damage from abrasion, wear, and harsh environmental conditions.
Precision Connectivity:Equipped with connectors that maintain tight and secure connections despite vibrations, heat, and other engine stresses.

Automotive Cable Assemblies

Lighting Cable Assemblies

Lighting cable assemblies in the automotive sector are specialized wiring systems designed to connect and power various lighting components in vehicles. These assemblies facilitate the operation of headlights, taillights, interior lighting, and auxiliary lighting systems, ensuring reliability, safety, and compliance with vehicle design standards.

Headlights:Includes connections for halogen, HID (high-intensity discharge), LED, and laser headlights. Supports features like adaptive beam control and daytime running lights (DRLs).
Taillights:Includes brake lights, turn signals, and reversing lights, often incorporating sequential or LED designs.
Interior Lighting:Connects cabin illumination, dashboard lights, ambient lighting, and reading lights.
Auxiliary Lighting:Wiring for fog lights, off-road lights, and emergency lights.
Decorative Lighting:Includes connections for underglow kits, wheel well lights, and custom aesthetic installations.

Automotive Cable Assemblies

Sensor and Actuator Cable Assemblies

Sensor and actuator cable assemblies in automotive applications are specialized wiring systems designed to connect various sensors and actuators to the vehicle’s electronic control units (ECUs). These assemblies enable precise communication, ensuring the vehicle operates efficiently, safely, and reliably. As vehicles evolve with advanced technologies, sensor and actuator assemblies play a critical role in implementing real-time monitoring, feedback, and control systems.

Signal Integrity: Designed to ensure minimal signal loss or interference, particularly for sensitive data from sensors. Often include shielding, such as braided or foil wraps, to prevent electromagnetic interference (EMI).
Durability: Built to withstand harsh automotive environments, including extreme temperatures, vibrations, moisture, and exposure to chemicals like oil or coolant.
Compact and Flexible Designs: Incorporates lightweight and flexible materials for efficient routing through tight spaces in vehicle architectures.
Precision Connectivity: Includes connectors that ensure secure and accurate connections for consistent performance.
Customized Solutions: Tailored to specific vehicle models or applications, with varying lengths, connector types, and insulation materials.

Automotive Cable Assemblies

Safety & Security Cable Assemblies

Safety & security cable assemblies are specialized wiring systems in vehicles designed to support systems that protect passengers, prevent accidents, and enhance vehicle security. These assemblies ensure seamless communication and power distribution to safety-critical systems like airbags, anti-lock braking systems (ABS), cameras, sensors, alarms, and electronic locking mechanisms.

Anti-lock Braking Systems (ABS):Cable assemblies connecting wheel speed sensors, control modules, and actuators.
Traction Control and Stability Systems:Wiring for electronic control units (ECUs) that adjust power delivery and braking.
Advanced Driver Assistance Systems (ADAS):Connect cameras, radar, LIDAR, and ultrasonic sensors for features like collision warning, lane departure alert, and adaptive cruise control.
Airbags:Assemblies linking crash sensors, control modules, and inflators to ensure rapid deployment.
Seatbelt Pretensioners:Cables connecting tensioners to control units for improved passenger restraint during crashes.
Vehicle Alarms:Wiring for sirens, motion sensors, and control modules.
Keyless Entry and Immobilizers:Harnesses connecting electronic locks, key fobs, and ECU for secure access.
Surveillance Systems:Wiring for cameras and recording modules in advanced security setups.

Automotive Cable Assemblies

Hybrid and EV Cable Assemblies

Hybrid and EV cable assemblies are specialized cable systems designed to handle the unique requirements of hybrid and fully electric vehicles. These assemblies support high-voltage power distribution, charging, and communication within the vehicle, ensuring optimal performance, safety, and efficiency.

High Voltage Handling:Designed to operate at voltages ranging from 400V to 800V, with some advanced systems exceeding 1000V in commercial or performance EVs.
Thermal Resistance:Built to handle heat generated during high-power operation using materials like silicone or cross-linked polyethylene (XLPE).
Durability:Resistant to wear, abrasion, and exposure to chemicals like coolant and battery acids.
Shielding and Insulation:Comprehensive shielding (copper braiding, aluminum foil) to reduce electromagnetic interference (EMI).Thick insulation to prevent electric shock and ensure compliance with safety standards.

Automotive Cable Assemblies

Custom Wire Harnesses

Custom wire harnesses for the automotive industry are specially designed electrical assemblies tailored to meet the unique requirements of specific vehicles or systems. These harnesses bundle and organize multiple wires and cables to efficiently transmit electrical power and signals throughout the vehicle.

Tailored Design:Built to specific vehicle or system requirements, accommodating unique configurations, dimensions, and functions.
High Reliability:Designed to withstand automotive conditions, such as vibration, heat, moisture, and chemical exposure.
Simplified Installation:Pre-configured to streamline assembly, reduce errors, and enhance efficiency in manufacturing processes
Compact and Organized:Bundling wires minimizes clutter and ensures optimal use of space within the vehicle.
Enhanced Safety:Includes protective features like insulation, fuses, and grommets to prevent electrical faults and enhance durability.

Tailored Solution

RichCables^® offers top-tier customization With decades of expertise in designing, testing, and producing diverse wire harnesses and cable assemblies. Next, we are proud to offer an innovative portfolio that reflects our commitment to quality and versatility across a wide range of applications.

Explore our portfolio: Automotive Cable Assemblies

OEM Automotive Cable Assemblies: Custom wire harnesses tailored for vehicles, built to endure harsh conditions while ensuring power and system communication.

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Wire Harness Molex SL Modular Connectors 2.54mm pitch Terminal 3pins — Get the Quote

Wire Harness Molex SL Connectors 2.54mm pitch Terminal

Molex SL connectors have versatility, compact design, and adaptability across different applications and configurations, underscoring their reliability in demanding environments.

Crimp Termination for Reliability
Ease of handling for space-constrained applications
Modular design for tailored configurations
Wide Range of Options
Polarized and Friction-Lock Housings
Durable locking mechanism
Versatile compatibility

Wire Harness Molex KK Connectors KK396 3.96mm pitch Terminal

Friction lock headers for secure connections
Polarizing features to prevent mismating
Available with kinked PC tails for improved stability
Multiple terminal designs with enhanced contact points
Options for vertical and right-angle headers
Compatible with top, bottom, and right-angle PCB receptacles
Ensures reliable mating under various conditions
Optimized for high-current applications
Excellent contact integrity with the PCB
Designed to perform in high-vibration environments
Flexible design options to meet specific application needs

Wire Harness Molex KK Connectors KK254 2.54mm pitch Terminal

Friction lock headers and friction lock ramp housings
Polarizing back walls, housings, and pegs
Kinked PC tails
Ensures secure mating
Prevents mismating
Ensures good contact with the PCB
Ideal for high-vibration environments
Design flexibility

Wire Harness JST SH Connector 1.0mm pitch Terminal

The JST SH Connector 1.0mm pitch Terminal is the world's first 1.0 mm pitch crimp style connector. It features a compact, low profile design in a wire-to-board configuration. Its unique contact engagement with the housing lance provides excellent performance in the contact insertion process when using smaller diameter wires. In addition, with a high-pressure contact design, the SH contact demonstrates excellent contact reliability providing an assured connection.

Compact and space-saving
Housing lance system
High-pressure contact design for a more assured connection
Socket compatible with IDC style SR connector

Custom Wire harness JST PH 2.0mm Pitch Disconnectable Crimp style Connectors — Get the Quote

Wire Harness JST PH Disconnectable Crimp style Connector 2.0mm pitch Terminal

The JST PH 2.0mm pitch Disconnectable Crimp style Connector is a thin, low-profile 2.0mm pitchconnector 8.0mm in height after mountingand 4.5mm in width. It is designed to meetthe demand for high-density connection ofinternal wires to printed circuit boards. It is compact, highly reliable and low in cost.

Reliable contact
Fully shrouded header
Printed circuit board retention mechanismSurface mount model (SMT)

Rich Cables Custom Wire harness JST GH 1.25mm Pitch Connector — Get the Quote

Wire Harness JST GH Connector 1.25mm pitch Terminal

The JST GH 1.25mm pitch connector is a 1.25 mm pitch, wire-toboard connector with a secure locking function. It is suitable for internal connections in various electrical and electronic equipment for high density applications. Low insertion force contacts allow for ease of mating with a positive tactile clicking sensation, providing a highly reliable connection.

Secure lock mechanism
Superior mating performance
Large outer latch for positive lock
Structured to prevent contact deformation
Housings are designed to prevent incorrect mating

Rich Cables Custom Wire harness JST EH 2.5mm Pitch Connector — Get the Quote

Wire Harness JST EH Connector 2.5mm pitch Terminal

The JST EH 2.5mm pitch connector is a 2.5 mm pitch low-profile, wire-toboard connector that meets the needs of high density PCB requirements and provides design flexibility in all sorts of electronic devices. The top entry type is 3.8 mm in thickness and 8.1 mm in height. The low profile design helps to save space. The contact design provides a high-reliability connection. The EH series also offers excellent harness workability and is easy to mate and unmate.

Low-profile, space-saving design
High-reliability contacts
Shaped to prevent misinsertion
Excellent workability in the wire harness assembly and mating process

Wire Harness JST XH connector male plug 8pin wiring connector — Get the Quote

Wire Harness JST XH Connector 2.5mm pitch Terminal

The JST XH 2.5mm pitch connector/Crimp style and Mating style is a highly reliable, versatile wire-to-board connector designed to meet the demands of modern electronic Wire Harness applications. Its 2.5mm pitch makes it ideal for connecting wires in low-cost consumer electronics and compact devices. The XH series offers a robust solution for low-profile applications with an assembled board height of just 9.8mm.

Original double-leaf contact design
Box-shaped shrouded header
Header is also available with boss
The 4 pin version conforms to JEMA's
Home Automation (HA terminal) standards.

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