Development of a Safe and Reliable Wiring System for Electric Utility Vehicle

Electric utility vehicles (EUVs) rely on a complex electrical wiring network linking traction battery packs, motor controllers, propulsion motors, onboard chargers, and low-voltage auxiliary loads.Inadequate conductor sizing, deficient overcurrent protection coordination, improper crimp terminations, cable chafing, and unprotected harness routing introduce risks of thermal runaway, severe voltage drop, functional loss, and vehicle fires.This paper presents a structured engineering design methodology for developing an optimized, safe, and easily inspectable wiring harness for an electric utility vehicle.The proposed methodology establishes baseline component ratings, analytical cable sizing models based on permissible voltage drop and thermal derating factors, coordinated circuit protection, and physical segregation of traction and control lines.A systematic multi-stage electrical and thermal verification framework is formulated to guide bench testing, harness assembly, and vehicle-level validation.