As
cable harnesses are already among the most complex and heaviest components used
in vehicles, any possibility for weight savings is an attractive proposition. A
model calculation of realistic weight-saving potential was analyzed in an
average mid-size car with a cable harness weighing just under 30 kilograms. For
the substitution of Al wire for Cu conductors, exclusively larger cross-sections
(>0.75 mm²) were analyzed, excluding the fine-signal conductors. Al
conductors with the next-highest cross-section replaced the affected Cu
conductors. Under these conditions, a purely computational weight savings of
around 7kg was initially achieved. However, for the last decade in Germany, the
solid battery terminals were already made of Al, so the actual potential for
savings in this particular case study is 2-3kg per cable harness.
Colin Bennett on 08 Jul 09Sumitomo Wiring Systems (SWS), a subsidiary of Sumitomo Electric Industries (SEI) to manufacture automotive wiring harnesses and components, will start commercial production of aluminium-conductor wiring harness at Suzuka plant, Mie, Japan in autumn 2010 to supply Japanese major automaker. SWS changed layout of Suzuka plant partially and introduced productive facilities specialized to aluminium wiring harness in June. In future, SWS aims to increase aluminium wiring harness ratio to 20-30% of the total wiring harness production.
