Raytron Technical Review RESEARCH ARTICLE WP-07-10
Automotive Wiring Harness: CCA Implementation
Published: March 2026 Version: 1.0
DOI: 10.1000/raytron.WP-07-10
1. Introduction
1.1 Automotive Wiring Complexity
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MEDIA TODO| Vehicle Type | Wire Length | Weight | Harnesses |
|---|---|---|---|
| Compact | 1-2 km | 20-30 kg | 30-50 |
| Mid-size | 2-3 km | 30-50 kg | 50-80 |
| Luxury/EV | 3-5 km | 50-80 kg | 80-150+ |
1.2 Weight Impact
| Vehicle | Wiring Weight | % of Curb Weight |
|---|---|---|
| ICE vehicle | 30-50 kg | 2-3% |
| EV | 50-80 kg | 3-5% |
| Target reduction | 10-30% | - |
2. Automotive Wiring Requirements
2.1 Electrical Requirements
| Circuit Type | Current | Voltage |
|---|---|---|
| Lighting | 5-15 A | 12V |
| Power | 10-40 A | 12V |
| Motor drives | 20-100 A | 12-48V |
| EV high voltage | 100-500 A | 400-800V |
2.2 Environmental Requirements
| Factor | Condition |
|---|---|
| Temperature | -40 to +125°C |
| Vibration | High (engine mount) |
| Flexibility | Required |
| Chemical resistance | Fluids, fuels |
| Fire resistance | Required |
2.3 Standards
| Standard | Scope |
|---|---|
| ISO 6722 | Wire specifications |
| SAE AS6722 | Aerospace equivalent |
| LV 112 | German automotive |
3. CCA Advantages
3.1 Weight Savings
| Cu Size | CCA-80% Equivalent | Weight Savings |
|---|---|---|
| 14 AWG | 12 AWG CCA | 55% |
| 12 AWG | 10 AWG CCA | 55% |
| 10 AWG | 8 AWG CCA | 55% |
3.2 Cost Savings
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MEDIA TODO| Component | Cu Cost | CCA Cost | Savings |
|---|---|---|---|
| Wire material | High | Moderate | 30-40% |
| Harness assembly | Same | Same | - |
| Total harness | Baseline | Lower | 15-25% |
3.3 Performance
| Property | Cu | CCA |
|---|---|---|
| Conductivity | 100% | 80% |
| Weight | Heavy | Light |
| Flexibility | Good | Good |
| Termination | Easy | Easy (Cu surface) |
4. Implementation Considerations
4.1 Circuit Selection
| Circuit Type | CCA Suitability |
|---|---|
| Lighting | Good |
| Low-power signal | Good |
| Power circuits | Size appropriately |
| High-current | Size appropriately |
| High-voltage (EV) | Evaluate per application |
4.2 Sizing Guidelines
| Cu Size | CCA-80% Size | Derating |
|---|---|---|
| 18 AWG | 16 AWG | Upsize 2 gauges |
| 16 AWG | 14 AWG | Upsize 2 gauges |
| 14 AWG | 12 AWG | Upsize 2 gauges |
4.3 Termination
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VIDEO TODO | Connection Type | CCA Practice |
|---|---|
| Crimp terminals | Standard Cu-rated |
| Wire-to-wire | Standard connectors |
| Bus connections | Standard |
4.4 Temperature Considerations
| Application | Max Temp | CCA Suitability |
|---|---|---|
| Cabin wiring | 85°C | Good |
| Engine bay | 105-125°C | Good with proper insulation |
| Near exhaust | >125°C | Evaluate |
5. Qualification Process
5.1 Testing Requirements
| Test | Standard | Purpose |
|---|---|---|
| Electrical | ISO 6722 | Conductivity |
| Mechanical | ISO 6722 | Strength, flexibility |
| Environmental | ISO 6722 | Temperature, chemicals |
| Vibration | OEM spec | Fatigue |
| Fire | ISO 6722 | Flame resistance |
5.2 OEM Approval
| Step | Activity |
|---|---|
| 1 | Material qualification |
| 2 | Component testing |
| 3 | Harness qualification |
| 4 | Vehicle validation |
| 5 | Production approval |
5.3 Documentation
| Document | Content |
|---|---|
| PPAP | Production approval |
| Test reports | Qualification data |
| Process specs | Manufacturing |
6. Conclusion
6.1 Summary
| Benefit | CCA Automotive |
|---|---|
| Weight savings | 50-60% |
| Cost savings | 15-25% |
| Performance | Good (sized properly) |
| Qualification | Standard process |
6.2 Implementation Strategy
- Start with low-current circuits
- Size appropriately for current
- Follow qualification process
- Validate in application
7. References
- ISO 6722. (2022). Road Vehicles - 60V and 600V Single-Core Cables.
- SAE AS6722. (2020). Aerospace Wire Specifications.
Frequently Asked Questions
Which automotive circuits are best suited for CCA?
CCA is ideal for lighting circuits, low-power signal wiring, and standard power circuits. High-current circuits and EV high-voltage systems require careful evaluation and appropriate sizing.
How do I size CCA for automotive applications?
Upsize CCA approximately 2 AWG gauges larger than copper equivalent (e.g., 14 AWG Cu becomes 12 AWG CCA). Apply temperature derating for engine bay applications.
What qualification testing is required for automotive CCA?
Testing per ISO 6722 includes electrical (conductivity), mechanical (strength, flexibility), environmental (temperature, chemicals), vibration, and fire resistance. OEM-specific validation follows material qualification.
Can CCA be used in engine bay wiring?
Yes, CCA can be used in engine bay applications with proper insulation (XLPE or ETFE rated for 105-125°C). Apply temperature derating and avoid locations near exhaust components exceeding 125°C.