How wire harnessing drive innovation and automation in the commercial vehicle industry

Three key trends are driving this growth. First, rising volumes of parcels and e-commerce — the number of parcels shipped globally will treble from 100 billion in 2019 to 300 billion in 2026. Second, a steep rise in international and domestic trade, estimated at 8% for 2021. And third, the need for governments worldwide to make CVs safer and more environmentally friendly. This last trend is particularly important. The number of fatalities caused by CVs, whether due to human error or vehicle malfunction, is high, especially in emerging markets. Moreover, emissions from conventional combustion engine CVs are significant.

These issues are prompting fleet owners to upgrade their existing CVs. On the energy front, they are turning to new energy powertrains, alternatively powered by hydrogen fuel cells for long-distance logistics delivered by heavy-duty trucks (HDT) and medium-duty trucks (MDT), or batteries for urban deliveries by light commercial vehicles (LCVs). By 2030, more than one-third of the LCVs globally will be new-energy vehicles, with HDTs accounting for one-quarter of the global fleet.

In terms of other emerging technologies, CV operators are leveraging autonomous vehicles (AVs) to make the driving experience safer, more for long-haul journeys than for first- and last-mile deliveries.

Flexibility and the ability to repair with ease are key to this new-generation framework being effective. Unlike most of the other 30,000 components that make up today’s average vehicle, wire harnessing is typically installed manually rather than via robotics. High-end systems are usually made from one of three materials, being either cloth-, fleece- or film-backed — they must be heat-reflective, and be able to withstand high temperatures while protecting increasingly diverse and sensitive wiring.

Harnessing must be flexible to fit between panels and various control elements of the CV — such as the engine, steering and suspension systems. On top of that, it requires a high-quality adhesive to hold it in place — protections that help reduce the risk of wires and the vehicle’s electrical circuits shorting.

Equally as important is the wire harnessing’s weight. Given the sheer quantity of wires lining today’s vehicles, some materials will naturally add more weight than others — leading to increased fuel consumption and a bigger carbon footprint. This feature is significant, as regulators and auto manufacturers are now striving to make vehicles more environmentally friendly.

Our wire harnessing solutions made of cloth, fleece, and filmic backings feature high-quality adhesives. tesa harness coverings securely bundle harnesses while protecting them from extreme temperatures and demanding environmental conditions — thanks to our proprietary heat-reflective solutions that offer best-in-class reflexibility and heat reflection, and are easy to apply. Furthermore, our solutions for the engine compartment are resistant to high abrasion, and in the driver compartment, our solutions reduce noise significantly.

The above solutions are a reflection of tesa’s brand characteristics: we are approachable, always putting our customers and people first; we are responsive, acting swiftly to market moves and customer demands; and we are reliable — our suite of solutions from across multiple industries are built on quality and expertise, ensuring optimal performance, no environmental impact, and paramount human safety. Indeed, as the CV market globally strives to be more sustainable, tesa will continue to play a critical role in its transformation.