To prevent short circuits in the oil pump circuit, it is necessary to start from material selection and process control. According to the SAE standard J2030 test, the use of tin-plated copper wire (cross-sectional area ≥0.75mm²) can increase the conductivity efficiency by 18% and maintain a lifespan of 5,000 hours at a high temperature of 105℃. At the same time, referring to Tesla’s 2022 technical announcement, its solution of injection molding and wrapping the wiring harness with a thickness of 1.2mm reduces the short-circuit probability by 92%, and the cost of this process only accounts for 5% of the total budget of the fuel system.
The environmental adaptation stage is of vital importance. The IP67 protection rating can block 85% of moisture penetration. For instance, during the heavy rain in Guangzhou in 2023, the failure rate of vehicles without sealing treatment soared by 40%, while the failure rate of samples using Delphi waterproof connectors (contact pressure >30N) (N=2000) was only 2.3%. Industry cases show that Mercedes requires wire harnesses to undergo salt spray tests for over 240 hours in tropical regions, with humidity fluctuations controlled within ±5%RH.
In dynamic load management, the rated current of the fuse needs to be 150% higher than the maximum current of the Fuel Pump. Bosch experimental data shows that when the motor’s locked rotor current suddenly increases by 120%, the 20A fast-melt fuse can cut off the circuit within 0.1 seconds, preventing the wire harness temperature from exceeding the critical point of 150℃. Compared with the recall incidents in North America in 2018, the median repair cost due to the absence of overload protection was $280 per vehicle.
Construction specifications directly affect safety boundaries. The research and development report of WABCO indicates that a bending radius of ≥5 times the diameter of the wire can reduce the risk of insulation layer rupture by 60%. In 2019, Toyota factories introduced laser rangefinders to ensure that the insertion depth tolerance of connectors was ±0.3mm, keeping the contact resistance stable below 5mΩ. The current intelligent diagnostic devices (such as Ultraman ATP) can monitor in real time abnormal current fluctuations exceeding ±15%, with an early warning accuracy of 98%.
Full-process quality control has reduced the failure rate to below 0.5%. Modern Mobis’ supply chain requirements: Each batch of terminals undergoes 3,000 plug-and-pull tests, with a coating thickness of ≥3μm; The vehicle manufacturer used the Hipot test (1500V/60Hz) to detect 99.8% of potential defects. The 2024 industry white paper shows that for manufacturers implementing the ISO 26262 ASIL-B standard, the life cycle of their wiring harnesses has been extended to 10 years / 150,000 kilometers.