I'm an electronics design engineer and can say this was exceptional, drawings, graphics, animation, script, content, editing and audio. Including the spec numbers showed a complete understanding of the topic. Well done, thank you to everyone at New Mind.
I am an automotive diagnostician and I specialize in wiring systems - OEM and custom with avionics experience. I enjoyed this video before I hit the play button. I am excited to see you leave something in the chat box. Thank you.
Mechanical engineer here. Tell me again why a failed tail light on new Ford pickup trucks cost $4,500 to repair. I don't care how great the drawings are, that is very poor design.
I was an engineering manager in wire harness manufacture for over 40 years, and have never seen such a complete and accurate presentation of electrical wiring in vehicles !
Hey Which software do you use for Designing and simulation of Wire Harness Design? And can you provide any resources for Learning as I am also An electrical Engineer with an interest in Automotive wiring. Thanks
I've been retired for a few years now, so am not right up to date. In my day, the customers designed the wire harnesses. Most of them used Pro-E (or whatever that is called today). Because they never took the time to enter the parameters of the components, their designs were full of errors. We developed in-house software to cross-reference all the items they specified (wire, terminals, seals, connectors), and sent them a list of errors, which they sometimes repaired on their drawings. Otherwise, we just made the corrections ourselves, frequently getting in trouble with their quality departments because our harnesses weren't (and couldn't be) "built to print". As I was exiting the field, more and more customers were putting pressure on the harness suppliers to design the harnesses for them. (Of course they didn't want to pay for that!)
I toured the Lockheed plant in Fort Worth, Texas (where they build F-35 jets, etc) They had huge tables set up with guides to run the wires on, some had to have been 30 feet long, hundreds of wires, ita how they laid out the wiring harnesses, was neat to see it like that.
I worked at car restorations with a friend as a hobby from 1982 to 2000. The first one I restored was a 1952 Chevy pickup. We didn’t have a wiring diagram, but the harness was so simple that we didn’t need one. The next one was a different story. It was a 1970 302 Boss. There was nothing wrong with it mechanically or bodywise. The insurance company totaled it because of faults in the wiring harness. I found out from an adjuster that insurance companies considered wiring harnesses to be unreparable after 5 years because the insulation gets brittle and cracks when disturbed. Fortunately, we had a source that could get us original wiring diagrams for almost anything. I designed a pegboard that allowed me to run all the wires before termination and looming based on a film I had seen on late night TV showing a wiring harness being built in the 60’s. The Boss was the first time I tried it, and it worked perfectly. The assessor never even noticed it wasn’t original. The only reason I stopped was because I only knew wiring and my friend died (he was 80). We preffered pre 1980 cars because after that there were so many different types of wire required that it was costing a fortune. We always tried to restore to factory original, with the exception of paint. We left that up to the buyers. I did it as a hobby, but it was a business for my friend. He actually believed Social Sucurity would be enough, so he needed the money. My favorite was a 72 Challenger, but the most impressive was a 73 Duster. That car was just a freak. Unfortunately, the buyer wrecked it a week after he bought it. We salvaged the drive train, and we were going to put it in a street rod, but we never finished it. We did about 6 cars a year, mostly muscle cars. I look at the wiring harnesses in today’s cars and I don’t have a clue.
You would probably enjoy wiring a modern race ECU from scratch, Im doing exactly that for my 89 MR2 SC and updating it with modern individual coils and wastegate control and sensors, its taught me quite a lot, especially since Im using the stock motor and stock chassis harness. Also as someone who also works on modern cars as a mechanic professionally, I can say its given me a lot better understanding of the core functions of a modern wiring harness, without all the VVT controls and useless sensors and bs. I fucked up the first attempt at the wiring harness and now I'm going back to use mil spec connectos and do concentric twisting, then cover it all in heatshrink rather than the vinyl mesh type I used before. Its been a hell of a learning process and the projected cost has tripled, but the final result is all going to be worth it I know.
@@kylesebring My brother in law did a street rod using split plastic corrugated tubing. At first he was angry because all he could get was red, not black. When he was done, it looked so good his customer decided to leave it open engine instead of hood and side panel style cowling. Really made it pop. Personally, the most confusing I ever did was a 1960 VW Bug. It took forever to wrap my head around how it worked. That was when I realized you have to understand it to build it properly. I was an instrument and controls tech for most of my career. My hobby contributed greatly to my successful career. Before I retired, I was getting calls from all over the western US to come and rebuild control systems from plant managers who had seen my work. The whole reason my work looked so good was from what I learned building wiring harnesses. I do wish auto manufacturers would learn a few things about PLCs though…
@@Simple_But_Expensivea child can figure out a 1960 vw beetle wiring harness. If that don’t make sense Sorry you weren’t meant for automotive wiring As the entire Harness fits on one page diagram. Literally it’s as complex as a 1930s car.
@@fastinradfordable Yes, I know, but for some reason it just didn’t make sense to me. It took literally days for me to wrap my head around it. The 52 Chevy was easy even without a wiring diagram. The muscle cars were easy, just tedious. On the VW, for some reason I just blanked. Can’t explain it, it just was. I have rewired about 7 Bugs (58-70) since with no problem, but that first just faceplanted me for about 3 days.
And for all that complexity, they totally forgot about fault-tolerance, robustness, repairability, and reliability. It's not just sticker-shock that makes people not want to buy new cars.
@@VladGoro25 When I first started, I thought something was wrong that a 66 pin Autosport connector was $400 for the pair plus the cost of terminals. Now I know that its just part of the business and have no problem justifying 15-20k for a more exotic engine harness. The time to concentric twist everything, to shrink it, boot it plus connectors costs a lot of money, but the results are awesome.
Your ability to pronounce the modern day insulation materials without a stutter or any mishaps goes to show just how much effort and care goes into your content. Being a technician myself, I would have made the effort to pronounce those words correctly, but only once. I would focus on the acronyms and the various applications if it was my script. Great video. This is incredibly detailed and highly educational. I will probably view this one a few times this week.
Outstanding video! I am a marine systems tech working on everything from basic DC to drive-by-wire control systems for Mercury, Volvo, and Yamaha. I will show this video to our service department!
That's what the pros say themselves. Modern cars are overly complicated electronically and will break more often and be harder to fix because of numerous badly thought out interdependencies as well as blatant anti consumer (and anti non licensed mechanics) design and programming.
@@AJ-ln4sm You don't sound like the kind of person who can help themselves or others. Me? I started doing my own appliance repair at 7, fixed a washing machine and it cost my mom only $15 for a new solenoid valve. Then I fixed the heating element in our dryer, I fixed several CRT TV's despite the "danger", I did my own complete brake job recently swapped out my stock brakes for some TSX brakes of the same year (I have a Honda) so it was a nice upgrade in stopping power without losing ABS, etc. I flushed the lines twice just to make sure it was all new brake fluid. I did my own research and learned which kind of thread locker you want to use, bought the manual and got the torque to spec. I've saved easily ten grand in my reasonably short life of 33 years. You sound like the sort who just pays someone else for everything you do and I have to say I don't respect those kinds of people. They're no help in an emergency.
One of the biggest changes in the automotive wiring is 10Base-T1S standard. This is basically 10Mbps ethernet, but over a single pair (normal 10Base-T uses 2 pairs, and 1000Gbps uses 4 pairs). It is a high speed, muilti-drop and optionally collision-less standard, that is highly compatible with standard ethernet. There are also 100 and 1000 Mbps variants (more for cameras and lidar applications), as well a separate but similar standard called 10Base-T1L, with high range (it is not used in automotive, with primary applications being industrial and building automation). They can also provide power to low power devices without extra cabling. In cars, these standards will likely displace CAN, LIN, and other similar tech, either by native Ethernet / IP traffic, or tunneling CAN and LIN. The estimated benefits are reducing cost and weight of the wiring harness by half, while providing higher performance.
15:15 What all of these bad boys have in common is that they are pretty tough to seperate without breaking thier locking mechanisim. Especially when they are caked up with dirt. 21:25 This by the way works only semi well in practice. Since every manufacturer is allowed to be thier own special shade of wierd and only a few of the diagnostic codes are normed for emmisson related errors. Even expensive and fancy interfaces like Gutman or Autel Struggle to get anything out of lets say something goofy like an Iveco Daily. The bus systems in general are among the most bullet proof things on cars today. That is as long as a manufacturer doesnt suffer from the big dumb and decides to expose the wires to places where they can break from bending or scrape open from bottoming out. (Yea ive seen this before) 22:50 Biggest thing about HV vehcles is that instead of having the chassi as a ground it runs HV-ground back to the battery via a seperate wire. All HV wires are bright orange and are constantly being checked by a pilot line. Even if you really wanted to hurt your self with the HV system youd need to be very intentional and know what youre doing.
I first encountered cannon plugs in the Navy. I always thought they were called that because they resembled the end of a cannon. Thanks for the extra tidbit of information I wasn’t expecting!
Cannon really changed the game for a lot of industries. I work in live entertainment and daily we use various forms of the XLR connector, which started out as the Cannon X series, then they added the latch feature, so it became the XL connector and then they added the rubber insulation between the pins on the female side, resulting in the final XLR connector that every sound and lighting tech uses daily. Though these days most XLR connectors are manufactured by Neutrik or Amphenol.
I am addicted to watching all of your automotive related videos, as of now I have watched this video 7 times and will probably continue to go back and watch others. As an automotive service technician I thank you for your high quality content and so many automotive videos. I recommend your channel to as many other technicians as I can
This video popped up on my feed, not expecting much I clicked on it. I found it very interesting and was blown away by the amount of information packed into it. What an awesome job, well done!
Thank you for having such a wonderful channel - one that avoids clickbait, and which covers exactly what the video says it will. It is the most welcome breath of fresh air on TH-cam, and it’s the reason I always watch your videos. And I’m sure it’s also the reason your channel will keep growing.
Those high pin count circular connectors are so 😍🥰 Browsing through catalogs of 38999 style connectors one will find that the sheer number of options and resulting part numbers is absolutely bewildering 😊
An oddly relevant video for me as I am in the process of going through wiring from 3 different generations of vehicle to create a hybrid wiring harness allowing the transplant of a more modern fuel injected engine into an older car from 1987. Thank you for the historical perspective!
I fix new car wiring every day. My own vehicle has a mechanical diesel that doesn’t even need a battery That’s a true working man’s car. It don’t take a hundred engineers and specialty sourced materials for basic function😂
This video was stellar. The menagerie of connectors that hobby makers come across is daunting, so having accessible explanations like this is a great comfort. Thank you!
That was a brilliant video on basically the history and breakdown of any electrical control system. I have been working in the electrical system automated controls fields for over 25 yrs and currently support large number of engineers with no or little electrical knowledge in large projects with system controls as a vital component. The fact that it is about vehicles makes it easier to absorb from a non technical electrical mind since every human has a constant personal contact with a car. The principles, control systems, wiring, equipment protocols, developments and explanations allow the information you provide in this excellent visual format, to be taken into other electrical control fields as an exemplification. outstanding video and content that you have produced, the delivery of this in the various formats and visual techniques is brilliant work. Thank you.
As an automobile electrical harness engineer myself, working for customers like Piaggio, Aprilia and sometimes Isuzu, it takes so much effort & focus to accurately prepare a single harness & much more hassle for consistent mass production.
Excellent video, you touched on the finer points that most skip over. 2 decades ago exactly I started as a Chevy apprentice tech program and did the factory level training in electronics in both OBD 1&2. Going a bit deeper on OBD 2 and SRS (airbag/ restraint) systems would make for another good video.
This was outstanding! When I started as a Mechanic in the mid seventies wiring seemed complicated. When electronic ignition came out we thought, how will we ever diagnose this black box mystery!
As an Embedded electronics engineer, I can say, like many others here, that this video is just brilliant! I particularly loved the way you presented the humble beginnings of the automotive industry, comparison with aviation, advancements in chemical engineering, to the description of the communication protocols. In the beginning of the video, I was expecting CAN would get a brief mention, but you went way beyond it! I wish a content this good was available when I was a student 😊
As clydecessna737 pointed out earlier, showing an image of a Soviet era AN-2 at 6:22 is lazy video editing. Just because it's a biplane doesn't mean it's a reasonable representation of American combat planes from a century ago. This really good video deserved better attention to detail.
What a great video! This has been the absolute best explanation of not only modern day wiring harnesses, but the history of them all. As a car enthusiast and past automotive engineer/master craftsman, I feel this is a great video for anyone wanting, or needing to grasp automotive electronics. Great work!
This is highly educative video for free. I appreciate the huge effort you put into this material, it is fascinating! It helped me a lot as I am exploring automotive industry!
This was a professional well-done video! The next video needs to be on the next chapter, which has just been written. The Cyber truck moved to a 48v system and an Ethernet loop, moving past the Boch CAN BUS system. Well done! Great history lesson.
Understanding the history and the reasons why different technologies were developed is not only interesting, but a big help when putting projects together. Great video. THank you!
As somewhat of a 3d printing nerd, its insane how much technology came from the Automotive sector. From basic things such as ABS, PP, and NYLON, to essential connectors such as Canbus and SPI; it all came from the Automotive sector 😲
Uhhhh… no? Of all the things you listed, CAN bus was the only thing expressly designed for automotive use. Everything else was _used_ in automobiles, but not specifically designed _for_ them.
You can always tell an aircraft mechanic because every connector is a (cannon plug). When I switched over to heavy equipment I got a lot of strange looks. Great video
You have created a great video, but it should be renamed to: "the horrifying evolution on how to overcomplicate and add unnecessary cost to a car" Im a computer engineer and I love electronics, but I also hate electronics in cars since almost everything is locked down, overpriced and expensive to replace and generally hard to troubleshoot making newer cars with electronics a pain for DIYers like myself.
As an apprentice auto technician, the starting point of my career basiclly socked with moedrn electronic control system, everything are digitized and electrified. Even through my experience and skill are still limited, I can tell that on modern cars, mechanical problems are actually less than older vehicles yet harder to fix, since most times they are burried by wires and connectors. Electrical problem on the other hand, are far more frequent and odd (I mean differs on each vehicle), other then some common issues usually lead by poor design or manufacture defect (I blame budget control in most cases), two identical symptoms may casued by totally different cause on two same vehicles. To me, the can or lin bus system itself is very reliable, wires do not just go bad as time passed (some will, high heat or outer element do destory them), connectors are also fine in most cases unless high current burns them out, but acutators and sensors are not, they do tend to go bad without warning some times. Now we are living in an era that EVs may wipe out ICE cars (Please don't, I pray for it), I am curious about what is coming next on vehicle control system.
You just earned yourself a new subscriber. Brilliantly done video. I'm a car guy and I love cars. I also love learning about the evolution of cars and car components. And you've got it all. Great footage, very good animation, good script, great editing, going into details including specs and standards and a pleasant voice and no begging for subs and likes. Keep it up my man! You're awesome!
I have a masters degree in embedded systems. And this video should be in curriculum. it is so well made. thank you for making it. I can understand the efforts that went in for this video. thank you so much!. Love form india.
Yes the can bus, the reason a headlight costs 10x more than a normal bulb would. I mean some engineer is happy about it right? There is no reason every light needs a processos to run on a can bus yet here we are. Running 3 and 4 wires instead of 2. Awesome technology, completely done in all the wring places.
Engineers don’t usually add features to a product in order to raise the price. They add features because it’s cool to add them. Management usually “requests” that features get added in order prices may be increased. There could be a regulatory requirement for being connected to the network. Or the extra wire or two could not be for can bus at all. It would have to be two wires for the network so if there are three wire it isn’t connected to can bus. The extra wires could be for daytime running lights and shifting between high and low beams, for just two examples.
Love your content! I think a video about the history automotive lighting/signaling and the optics that make it work would be fascinating. It seems that many take that aspect of automotive design and engineering for granted.
Appreciate your efforts that you solely focused on wires and connectors in a huge detail. We would also love to see such a lovely detailed video on Wire Harnesses and various materials, methods and styles adapted in the automotive and Aerospace industry. Thank you.
I'm surprised you didn't mention the Cybertruck which not only made the switch to 48V but also uses ethernet and controllers in a token ring like setup.
Never realized how big a nerd I am until I got excited by this. Like a lot of other people in the comments I work in a pretty closely related field (embedded SW for ag machines) and it’s interesting to see how far we’ve come
I worked in a startup that was targeting automotive communication applications for a while. There is some really complex stuff going on there, and people are trying different approaches to solve the problems. With ADAS in mind, people are looking to have sensors such as cameras and radars transmit uncompressed, raw data. Some expect this will push the data rate seen in the automotive wiring to above 50 gigabit/second. Currently there are two standards for 10 gigabit and 25 gigabit based on ethernet, one being copper and one optical. There are also some other standards such as automotive MiPi. However, for future upgrades, it is unlikely more than 25 gigabit/second can be transmitted over a single twisted pair of copper in an automotive environment---the loss the signal experiences is simply too great to carry it over the distances required. Optical is met with a lot of skepticism, because people are worried it will be fragile w.r.t. the vibrations a car experiences, and the optical lasers and diodes used for data center will not work at the elevated temperatures faced in vehicles. There are interesting new technologies, like millimeter-wave over dielectric waveguide, which I worked on, but it still requires some R&D to get to a point of commercial viability.
New mind... you make vids on stuff that not many would wanna dare try to make as they take so much time and research than many other things such as how fuel injection got better or such. Thank you so much!
Great work, I was impressed by the relevance of the used videos and pictures. It must have been hard to find all of those and then create some. The result is excellent.
With the raise of more digital systems and interconnectivity in cars also raised the risk of theft. In a documentary I saw a thief using a handheld device to start the car. A similar thing told me an elevator technician: Cyber security became a new thing in the industry because elevators become more connected. For example calling the elevator from your hotel room or your phone.
This was a bit outside of the scope of the video, but yes this is very true. Especially when many of these integrated components may never get security fixes or any sort of long term software support.
Working in aviation has brought me familiarity with canon style plugs and I’m also starting to learn more about digital communication systems. Wish I could like the video more than once!
I love working with older ring terminals and spade connectors, they're so DIY friendly. ATO fuses, bosch-style relays, and a few common switches and components all use the same size of spade connector. Making it easy for a home-gamer to customize or repair their own wiring. Newer connectors are a bit easier to (dis)connect and are waterproof, but there are so many different pin types and connector housings. It would have been nice if there was some more standardization. But car makers have demonstrated that they're more interested in obfuscating their components and making everything proprietary.
Amazing video. I didn’t give this any thought until Tesla showed their Ethernet wiring in the Cybertruck. This video helped me to understand how Tesla have stripped a ton of cost out of wiring.
You are underrated. The video might be hard to understand but it provides enough information for us normal folks to understand. I can see your passion, you had to study about many things just to make this video. Keep it up.
There has been an ongoing debate as to which is the more reliable connection--soldered or crimped. The video shows why crimped is the way to go and why it's used so much in applications where reliability (not just cost) is critical.
There a few applications where terminals are crimped and soldered. Or at least there was. I worked in maintenance at a factory producing wire harnesses for Ford and Chrysler for over a dozen years. Common applications of that type were high current circuits where the terminal was crimped and then dipped in a pot of molten solder. Another interesting one was terminals for power window switches. The wire cutting machine would cut, strip, apply flux, tin the wire, crimp the terminal, reflow the solder with a specially adapted spot soldering press and finally remove the flux in a solvent bath. Average production rate was around 20 pieces per minute.
Very well done. You incorporated a lot of good pics and videos. Only missing one terminal connector, but well before your time. I had a 1908 installed elevator, that may have been the very first ring terminals. (Stakons) To make connections of up to #6 copper wire, they took a 1-1/4" length of 1/4" copper tubing, flatten one end and drill a hole in it. Then they soldered a wire on one end and could either put the flattened end on a terminal or bolt them back-to-back in a motor box. Brilliant for 125 years ago😁
Exceptional work here, 44 years engineering in big auto harnesses world wide you have missed one little understood design aspect of the best automotive connectors. Shortly after the auto industry designed plastic shelled dedicated connectors with "click on insert, pull to test" terminals this was upgraded to "Yoka Poke" (fool proof assembly) connectors incorporated "locking keys" that must be inserted fully home and would only go fully home only if all terminals present were seated and home to depth correctly. These keys if not fully home would not allow the connectors to be mated so insuring all connectors were either assembled correctly or open circuit, NO INTERMITTENT CONNECTIONS, intermittent connections being the worst failure of automotive wiring. These fool proofing keys often worked as secondary latching systems and were confused as such as they were so similar however this was not heir prime function. Good test systems such as shown at 14:37 would detect a key not fully home or missing thus ensuring terminals were inserted fully into housings so catch the failures at manufacture however if not detected the harness could not be connected on the production line, a worse failure but not as bad as being connected with a badly seated terminal that would pass line inspection only to go intermittent on the customer at a later date, such a failure often difficult to diagnose.
The video was very good. I only missed a little bit in the end Tesla's latest development of their patented modular wiring system to cut down on 90+% of wires
This was great. I did not know about balanced serial communication. Now I've got something new to consider when making my wiring harness for my stuff. Great video. 😎👍
Great video for 2022 but You forgot where we are today: Wires have been slashed in number and size by running Gigabit ethernet cabling + data CANbus to every component- all on the same 48v cable. You can make a new video on it called "evolution of automotive wiring from 2023 on"
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That car actually did have a cylindrical plug :)
12:28
PLEASE make quantum computers part 2, you made part 1 ages ago and i've been waiting ever since
We don't like your color logo. Dislike ! Reported.
I liked your content, is it possible to take this video and translate it into Arabic and comment on it with my voice in Arabic language
I'm an electronics design engineer and can say this was exceptional, drawings, graphics, animation, script, content, editing and audio. Including the spec numbers showed a complete understanding of the topic. Well done, thank you to everyone at New Mind.
Thanks you, there’s nothing more fulfilling than a stamp of approval from an industry insider.
I know nothing about electronics design and I enjoyed it too. :)
I am an automotive diagnostician and I specialize in wiring systems - OEM and custom with avionics experience. I enjoyed this video before I hit the play button. I am excited to see you leave something in the chat box. Thank you.
@@YTInnovativeSolutionback at you, thanks and glad you chimed in as well.
Mechanical engineer here. Tell me again why a failed tail light on new Ford pickup trucks cost $4,500 to repair. I don't care how great the drawings are, that is very poor design.
I was an engineering manager in wire harness manufacture for over 40 years, and have never seen such a complete and accurate presentation of electrical wiring in vehicles !
Hey Which software do you use for Designing and simulation of Wire Harness Design? And can you provide any resources for Learning as I am also An electrical Engineer with an interest in Automotive wiring.
Thanks
I've been retired for a few years now, so am not right up to date. In my day, the customers designed the wire harnesses. Most of them used Pro-E (or whatever that is called today). Because they never took the time to enter the parameters of the components, their designs were full of errors. We developed in-house software to cross-reference all the items they specified (wire, terminals, seals, connectors), and sent them a list of errors, which they sometimes repaired on their drawings. Otherwise, we just made the corrections ourselves, frequently getting in trouble with their quality departments because our harnesses weren't (and couldn't be) "built to print". As I was exiting the field, more and more customers were putting pressure on the harness suppliers to design the harnesses for them. (Of course they didn't want to pay for that!)
Well, something's never change. Same now.
Capital XC @@HassanAli-fu7kj
Or Zuken e3
Automotive wire harness engineer here: You NAILED it! Nice job!
Can you do the wires of an AE-86?
What kind of drugs do you need to do to be a harness engineer ?
@@ElwoodHarpazoharness engineer here. I’ll take whatever you got to offer
I toured the Lockheed plant in Fort Worth, Texas (where they build F-35 jets, etc)
They had huge tables set up with guides to run the wires on, some had to have been 30 feet long, hundreds of wires, ita how they laid out the wiring harnesses, was neat to see it like that.
@@ElwoodHarpazothanks to wiring engineers too
I worked at car restorations with a friend as a hobby from 1982 to 2000.
The first one I restored was a 1952 Chevy pickup. We didn’t have a wiring diagram, but the harness was so simple that we didn’t need one.
The next one was a different story. It was a 1970 302 Boss. There was nothing wrong with it mechanically or bodywise. The insurance company totaled it because of faults in the wiring harness. I found out from an adjuster that insurance companies considered wiring harnesses to be unreparable after 5 years because the insulation gets brittle and cracks when disturbed.
Fortunately, we had a source that could get us original wiring diagrams for almost anything. I designed a pegboard that allowed me to run all the wires before termination and looming based on a film I had seen on late night TV showing a wiring harness being built in the 60’s. The Boss was the first time I tried it, and it worked perfectly. The assessor never even noticed it wasn’t original.
The only reason I stopped was because I only knew wiring and my friend died (he was 80).
We preffered pre 1980 cars because after that there were so many different types of wire required that it was costing a fortune.
We always tried to restore to factory original, with the exception of paint. We left that up to the buyers.
I did it as a hobby, but it was a business for my friend. He actually believed Social Sucurity would be enough, so he needed the money.
My favorite was a 72 Challenger, but the most impressive was a 73 Duster. That car was just a freak. Unfortunately, the buyer wrecked it a week after he bought it.
We salvaged the drive train, and we were going to put it in a street rod, but we never finished it.
We did about 6 cars a year, mostly muscle cars. I look at the wiring harnesses in today’s cars and I don’t have a clue.
You would probably enjoy wiring a modern race ECU from scratch, Im doing exactly that for my 89 MR2 SC and updating it with modern individual coils and wastegate control and sensors, its taught me quite a lot, especially since Im using the stock motor and stock chassis harness.
Also as someone who also works on modern cars as a mechanic professionally, I can say its given me a lot better understanding of the core functions of a modern wiring harness, without all the VVT controls and useless sensors and bs.
I fucked up the first attempt at the wiring harness and now I'm going back to use mil spec connectos and do concentric twisting, then cover it all in heatshrink rather than the vinyl mesh type I used before. Its been a hell of a learning process and the projected cost has tripled, but the final result is all going to be worth it I know.
@@kylesebring My brother in law did a street rod using split plastic corrugated tubing. At first he was angry because all he could get was red, not black. When he was done, it looked so good his customer decided to leave it open engine instead of hood and side panel style cowling. Really made it pop.
Personally, the most confusing I ever did was a 1960 VW Bug. It took forever to wrap my head around how it worked. That was when I realized you have to understand it to build it properly.
I was an instrument and controls tech for most of my career. My hobby contributed greatly to my successful career. Before I retired, I was getting calls from all over the western US to come and rebuild control systems from plant managers who had seen my work.
The whole reason my work looked so good was from what I learned building wiring harnesses. I do wish auto manufacturers would learn a few things about PLCs though…
@@Simple_But_Expensivea child can figure out a 1960 vw beetle wiring harness.
If that don’t make sense
Sorry you weren’t meant for automotive wiring
As the entire Harness fits on one page diagram.
Literally it’s as complex as a 1930s car.
@@fastinradfordable Yes, I know, but for some reason it just didn’t make sense to me. It took literally days for me to wrap my head around it. The 52 Chevy was easy even without a wiring diagram. The muscle cars were easy, just tedious. On the VW, for some reason I just blanked. Can’t explain it, it just was. I have rewired about 7 Bugs (58-70) since with no problem, but that first just faceplanted me for about 3 days.
And for all that complexity, they totally forgot about fault-tolerance, robustness, repairability, and reliability. It's not just sticker-shock that makes people not want to buy new cars.
As a 20yr business owner building motorsport harnesses, this is a great video for anyone that doesnt understand automotive electrical
so they don't complain when they are charged for 20+ pin connector purchase or repair. agree.
@@VladGoro25 When I first started, I thought something was wrong that a 66 pin Autosport connector was $400 for the pair plus the cost of terminals. Now I know that its just part of the business and have no problem justifying 15-20k for a more exotic engine harness. The time to concentric twist everything, to shrink it, boot it plus connectors costs a lot of money, but the results are awesome.
Your ability to pronounce the modern day insulation materials without a stutter or any mishaps goes to show just how much effort and care goes into your content. Being a technician myself, I would have made the effort to pronounce those words correctly, but only once. I would focus on the acronyms and the various applications if it was my script. Great video. This is incredibly detailed and highly educational. I will probably view this one a few times this week.
Thanks for noticing.
@@NewMind Be honest... Some of those took a few takes to roll off the tongue! :P
I just assumed it was computer-generated speech. They sound very human these days.
@@Hakucho64 if we hear someone who can speak technical, legalese, medical and pharmaceutical without struggle or error, then we can safely assume AI.
They also mix up simple homonyms, I think you're right. Like "wear" at 1:15
Outstanding video! I am a marine systems tech working on everything from basic DC to drive-by-wire control systems for Mercury, Volvo, and Yamaha.
I will show this video to our service department!
Working on modern day automotive electronics is the bane of my existence
Leave it to the pros
That's what the pros say themselves. Modern cars are overly complicated electronically and will break more often and be harder to fix because of numerous badly thought out interdependencies as well as blatant anti consumer (and anti non licensed mechanics) design and programming.
@@AJ-ln4smhe is the pro
@@AJ-ln4sm You don't sound like the kind of person who can help themselves or others. Me? I started doing my own appliance repair at 7, fixed a washing machine and it cost my mom only $15 for a new solenoid valve. Then I fixed the heating element in our dryer, I fixed several CRT TV's despite the "danger", I did my own complete brake job recently swapped out my stock brakes for some TSX brakes of the same year (I have a Honda) so it was a nice upgrade in stopping power without losing ABS, etc. I flushed the lines twice just to make sure it was all new brake fluid. I did my own research and learned which kind of thread locker you want to use, bought the manual and got the torque to spec.
I've saved easily ten grand in my reasonably short life of 33 years. You sound like the sort who just pays someone else for everything you do and I have to say I don't respect those kinds of people. They're no help in an emergency.
@@GeorgeWashingtonLaserMusket if you were a good looking girl, I'd marry you lol. I'm an engineer and I like repairing everything by myself :)))
Am an electrical automotive engineering student. I must say this is a complete, factural, easy to understand content about automotive wiring.
You don't owe us the highest quality, and yet you keep raising the bar with each video. Thank you so much!
One of the biggest changes in the automotive wiring is 10Base-T1S standard. This is basically 10Mbps ethernet, but over a single pair (normal 10Base-T uses 2 pairs, and 1000Gbps uses 4 pairs). It is a high speed, muilti-drop and optionally collision-less standard, that is highly compatible with standard ethernet. There are also 100 and 1000 Mbps variants (more for cameras and lidar applications), as well a separate but similar standard called 10Base-T1L, with high range (it is not used in automotive, with primary applications being industrial and building automation). They can also provide power to low power devices without extra cabling.
In cars, these standards will likely displace CAN, LIN, and other similar tech, either by native Ethernet / IP traffic, or tunneling CAN and LIN. The estimated benefits are reducing cost and weight of the wiring harness by half, while providing higher performance.
15:15 What all of these bad boys have in common is that they are pretty tough to seperate without breaking thier locking mechanisim. Especially when they are caked up with dirt.
21:25 This by the way works only semi well in practice. Since every manufacturer is allowed to be thier own special shade of wierd and only a few of the diagnostic codes are normed for emmisson related errors. Even expensive and fancy interfaces like Gutman or Autel Struggle to get anything out of lets say something goofy like an Iveco Daily.
The bus systems in general are among the most bullet proof things on cars today. That is as long as a manufacturer doesnt suffer from the big dumb and decides to expose the wires to places where they can break from bending or scrape open from bottoming out. (Yea ive seen this before)
22:50 Biggest thing about HV vehcles is that instead of having the chassi as a ground it runs HV-ground back to the battery via a seperate wire. All HV wires are bright orange and are constantly being checked by a pilot line. Even if you really wanted to hurt your self with the HV system youd need to be very intentional and know what youre doing.
BMW, Mercedes, Jaguar, and Land Rover have reported this video for hate speech.
lmfao
how it is always fascinating to see how much jem-packed your videos are
love your work
I first encountered cannon plugs in the Navy. I always thought they were called that because they resembled the end of a cannon. Thanks for the extra tidbit of information I wasn’t expecting!
I always thought they were made by the Japanese camera company, Canon.
@@slowerthansound not a bad theory either
I kind of wondered, but never gave it much thought as to why they had that name.
I think New Mind made a mistake here, Cannon Electric founder and inventor of the Cannon plug was James H. Cannon not Robert Cannon.
Cannon really changed the game for a lot of industries. I work in live entertainment and daily we use various forms of the XLR connector, which started out as the Cannon X series, then they added the latch feature, so it became the XL connector and then they added the rubber insulation between the pins on the female side, resulting in the final XLR connector that every sound and lighting tech uses daily. Though these days most XLR connectors are manufactured by Neutrik or Amphenol.
I am addicted to watching all of your automotive related videos, as of now I have watched this video 7 times and will probably continue to go back and watch others. As an automotive service technician I thank you for your high quality content and so many automotive videos. I recommend your channel to as many other technicians as I can
This video popped up on my feed, not expecting much I clicked on it.
I found it very interesting and was blown away by the amount of information packed into it.
What an awesome job, well done!
Thank you for having such a wonderful channel - one that avoids clickbait, and which covers exactly what the video says it will. It is the most welcome breath of fresh air on TH-cam, and it’s the reason I always watch your videos. And I’m sure it’s also the reason your channel will keep growing.
I don't do many comments but I just have to say this vidio is one of the best I have ever watched on so many levels. First class stuff.
Those high pin count circular connectors are so 😍🥰 Browsing through catalogs of 38999 style connectors one will find that the sheer number of options and resulting part numbers is absolutely bewildering 😊
We all just watched and enjoyed half an hour talks about electrical wire. Means this was extremely well made!
An oddly relevant video for me as I am in the process of going through wiring from 3 different generations of vehicle to create a hybrid wiring harness allowing the transplant of a more modern fuel injected engine into an older car from 1987. Thank you for the historical perspective!
I fix new car wiring every day.
My own vehicle has a mechanical diesel that doesn’t even need a battery
That’s a true working man’s car.
It don’t take a hundred engineers and specialty sourced materials for basic function😂
Great stuff. I’m hiring this guy to wire my house.
I like how you said house when the whole video was about automotive and aircraft wiring. Haha!
@@Hesthegreatest1 Thats because my cars don’t need rewiring, I don’t have aircraft, but I do have a house.
@@circusitch haha! I got you. Just making youtube banter.
I highly recommend a licensed electrician instead-most of them i know don't know jack about history but they'll do it faster than any historian i know
This video was stellar. The menagerie of connectors that hobby makers come across is daunting, so having accessible explanations like this is a great comfort. Thank you!
That was a brilliant video on basically the history and breakdown of any electrical control system. I have been working in the electrical system automated controls fields for over 25 yrs and currently support large number of engineers with no or little electrical knowledge in large projects with system controls as a vital component. The fact that it is about vehicles makes it easier to absorb from a non technical electrical mind since every human has a constant personal contact with a car. The principles, control systems, wiring, equipment protocols, developments and explanations allow the information you provide in this excellent visual format, to be taken into other electrical control fields as an exemplification. outstanding video and content that you have produced, the delivery of this in the various formats and visual techniques is brilliant work. Thank you.
As a professional waterpark salesman, great work! Nailed the content from my perspective.
I’m an automotive mechanic and I mainly do electrical work so this was cool to watch
As an automobile electrical harness engineer myself, working for customers like Piaggio, Aprilia and sometimes Isuzu, it takes so much effort & focus to accurately prepare a single harness & much more hassle for consistent mass production.
Exactly what a youtube video should be... perfect in every way
Excellent video, you touched on the finer points that most skip over. 2 decades ago exactly I started as a Chevy apprentice tech program and did the factory level training in electronics in both OBD 1&2. Going a bit deeper on OBD 2 and SRS (airbag/ restraint) systems would make for another good video.
This was outstanding! When I started as a Mechanic in the mid seventies wiring seemed complicated.
When electronic ignition came out we thought, how will we ever diagnose this black box mystery!
As an Embedded electronics engineer, I can say, like many others here, that this video is just brilliant! I particularly loved the way you presented the humble beginnings of the automotive industry, comparison with aviation, advancements in chemical engineering, to the description of the communication protocols. In the beginning of the video, I was expecting CAN would get a brief mention, but you went way beyond it! I wish a content this good was available when I was a student 😊
As clydecessna737 pointed out earlier, showing an image of a Soviet era AN-2 at 6:22 is lazy video editing. Just because it's a biplane doesn't mean it's a reasonable representation of American combat planes from a century ago. This really good video deserved better attention to detail.
0:17 "Stop jumping up and down or I swear I'll pull this car over and kick you *both* out!"
😂
😂😹
What a great video! This has been the absolute best explanation of not only modern day wiring harnesses, but the history of them all. As a car enthusiast and past automotive engineer/master craftsman, I feel this is a great video for anyone wanting, or needing to grasp automotive electronics. Great work!
This is highly educative video for free. I appreciate the huge effort you put into this material, it is fascinating! It helped me a lot as I am exploring automotive industry!
THIS, is quality content. Electrical engineer here, the topics and demonstrations were on point
like a time line of my life as an automotive electrician.
This was a professional well-done video! The next video needs to be on the next chapter, which has just been written. The Cyber truck moved to a 48v system and an Ethernet loop, moving past the Boch CAN BUS system. Well done! Great history lesson.
Agree, I was hoping this video would talk about that in the end, but perhaps/hopefully in another video in the future.
Understanding the history and the reasons why different technologies were developed is not only interesting, but a big help when putting projects together. Great video. THank you!
Thats why I quit been a mechanic and got in to IT for 20 years the wages did not reflect the technical expertise that cars required during the 2000s
I AM A SOCIAL IMPREGNATED ENGINEER, AND I CAN SAY THAT YOUR VIDEO IS EXCEPTIONAL, PHENOMENAL, SPECTACULAR, POPULAR, AND ON POINT
As somewhat of a 3d printing nerd, its insane how much technology came from the Automotive sector. From basic things such as ABS, PP, and NYLON, to essential connectors such as Canbus and SPI; it all came from the Automotive sector 😲
Uhhhh… no? Of all the things you listed, CAN bus was the only thing expressly designed for automotive use. Everything else was _used_ in automobiles, but not specifically designed _for_ them.
@@tookitogo Mmmmm sucks to suck. Still cool 😊
In the military we still commonly call the threaded ring circular connectors "Cannon plugs" regardless of who makes them.
You can always tell an aircraft mechanic because every connector is a (cannon plug). When I switched over to heavy equipment I got a lot of strange looks.
Great video
Model T engineer here, definitely spot on, im happy to see how advanced humanity got. Ill be back in 100 years and you better have an upda...💀
what an awesome video
You have created a great video, but it should be renamed to: "the horrifying evolution on how to overcomplicate and add unnecessary cost to a car"
Im a computer engineer and I love electronics, but I also hate electronics in cars since almost everything is locked down, overpriced and expensive to replace and generally hard to troubleshoot making newer cars with electronics a pain for DIYers like myself.
The degree of research that would've went in these videos is mind boggling. Kudos to you.
Excellent documentary, as always. Thank you!
This topic made me realise that you can make a video about anything and everything and still be informative.
As an apprentice auto technician, the starting point of my career basiclly socked with moedrn electronic control system, everything are digitized and electrified.
Even through my experience and skill are still limited, I can tell that on modern cars, mechanical problems are actually less than older vehicles yet harder to fix, since most times they are burried by wires and connectors.
Electrical problem on the other hand, are far more frequent and odd (I mean differs on each vehicle), other then some common issues usually lead by poor design or manufacture defect (I blame budget control in most cases), two identical symptoms may casued by totally different cause on two same vehicles.
To me, the can or lin bus system itself is very reliable, wires do not just go bad as time passed (some will, high heat or outer element do destory them), connectors are also fine in most cases unless high current burns them out, but acutators and sensors are not, they do tend to go bad without warning some times.
Now we are living in an era that EVs may wipe out ICE cars (Please don't, I pray for it), I am curious about what is coming next on vehicle control system.
You just earned yourself a new subscriber. Brilliantly done video. I'm a car guy and I love cars. I also love learning about the evolution of cars and car components.
And you've got it all. Great footage, very good animation, good script, great editing, going into details including specs and standards and a pleasant voice and no begging for subs and likes. Keep it up my man! You're awesome!
I have a masters degree in embedded systems. And this video should be in curriculum. it is so well made. thank you for making it.
I can understand the efforts that went in for this video.
thank you so much!.
Love form india.
I didn’t expect this video to include communication protocols. Well done!
your videos cover such interesting topics and are so well researched. it doesn't seem right that you don't get millions of views per video
Bravo! The quality of this video is top notch. Thanks a lot!
A first class Informative and crystal-clear presentation. Excellent !
A very well explained and thorough video. Thank you so much for sharing!
Thanks for sharing this amazing video with us! 💚
Yes the can bus, the reason a headlight costs 10x more than a normal bulb would. I mean some engineer is happy about it right? There is no reason every light needs a processos to run on a can bus yet here we are. Running 3 and 4 wires instead of 2. Awesome technology, completely done in all the wring places.
Engineers don’t usually add features to a product in order to raise the price. They add features because it’s cool to add them. Management usually “requests” that features get added in order prices may be increased. There could be a regulatory requirement for being connected to the network.
Or the extra wire or two could not be for can bus at all. It would have to be two wires for the network so if there are three wire it isn’t connected to can bus. The extra wires could be for daytime running lights and shifting between high and low beams, for just two examples.
@@capitalinventor4823love it when an expert answers a post thx 👍
Super thorough...RESPECT...👊
Love your content! I think a video about the history automotive lighting/signaling and the optics that make it work would be fascinating. It seems that many take that aspect of automotive design and engineering for granted.
The one of the best TH-cam channel in the World 🌎 ❤️
Appreciate your efforts that you solely focused on wires and connectors in a huge detail. We would also love to see such a lovely detailed video on Wire Harnesses and various materials, methods and styles adapted in the automotive and Aerospace industry. Thank you.
I'm surprised you didn't mention the Cybertruck which not only made the switch to 48V but also uses ethernet and controllers in a token ring like setup.
probably because its a joke of a car not worth mentioning! evs catch fire too much, nobody wants them.even hertz usa is selling off their evs.
Never realized how big a nerd I am until I got excited by this. Like a lot of other people in the comments I work in a pretty closely related field (embedded SW for ag machines) and it’s interesting to see how far we’ve come
Great video! Thank you New Mind ⭐✨
I worked in a startup that was targeting automotive communication applications for a while. There is some really complex stuff going on there, and people are trying different approaches to solve the problems.
With ADAS in mind, people are looking to have sensors such as cameras and radars transmit uncompressed, raw data. Some expect this will push the data rate seen in the automotive wiring to above 50 gigabit/second. Currently there are two standards for 10 gigabit and 25 gigabit based on ethernet, one being copper and one optical. There are also some other standards such as automotive MiPi. However, for future upgrades, it is unlikely more than 25 gigabit/second can be transmitted over a single twisted pair of copper in an automotive environment---the loss the signal experiences is simply too great to carry it over the distances required. Optical is met with a lot of skepticism, because people are worried it will be fragile w.r.t. the vibrations a car experiences, and the optical lasers and diodes used for data center will not work at the elevated temperatures faced in vehicles.
There are interesting new technologies, like millimeter-wave over dielectric waveguide, which I worked on, but it still requires some R&D to get to a point of commercial viability.
New mind... you make vids on stuff that not many would wanna dare try to make as they take so much time and research than many other things such as how fuel injection got better or such. Thank you so much!
Great work, I was impressed by the relevance of the used videos and pictures. It must have been hard to find all of those and then create some. The result is excellent.
With the raise of more digital systems and interconnectivity in cars also raised the risk of theft. In a documentary I saw a thief using a handheld device to start the car. A similar thing told me an elevator technician: Cyber security became a new thing in the industry because elevators become more connected. For example calling the elevator from your hotel room or your phone.
This was a bit outside of the scope of the video, but yes this is very true. Especially when many of these integrated components may never get security fixes or any sort of long term software support.
Do you mean unlock a car or start a car? Because starting a car was never a problem once you're inside
Working in aviation has brought me familiarity with canon style plugs and I’m also starting to learn more about digital communication systems. Wish I could like the video more than once!
What an amazing work. Great video, thank you.
Excellent coverage and presentation, very well done video; thank you!
I love working with older ring terminals and spade connectors, they're so DIY friendly. ATO fuses, bosch-style relays, and a few common switches and components all use the same size of spade connector. Making it easy for a home-gamer to customize or repair their own wiring. Newer connectors are a bit easier to (dis)connect and are waterproof, but there are so many different pin types and connector housings. It would have been nice if there was some more standardization. But car makers have demonstrated that they're more interested in obfuscating their components and making everything proprietary.
Informative, well produced, I must say this is a really good video
Amazing video. I didn’t give this any thought until Tesla showed their Ethernet wiring in the Cybertruck. This video helped me to understand how Tesla have stripped a ton of cost out of wiring.
This is so good. I like how it went to early aircraft electric connectors to car back again
The thumbnail summarizes why I hate working on anything made in the 21st century
Are you an electrical engineer? you have no idea how much i enjoyed it. TOP NOTCH... Subscribed!
Your work may have solved a communication issue I’ve battled with … nice job!
Excellent. Learned something new/ re-learned what I had forgotten.
Thanks.
You are underrated.
The video might be hard to understand but it provides enough information for us normal folks to understand.
I can see your passion, you had to study about many things just to make this video. Keep it up.
There has been an ongoing debate as to which is the more reliable connection--soldered or crimped. The video shows why crimped is the way to go and why it's used so much in applications where reliability (not just cost) is critical.
There a few applications where terminals are crimped and soldered. Or at least there was. I worked in maintenance at a factory producing wire harnesses for Ford and Chrysler for over a dozen years. Common applications of that type were high current circuits where the terminal was crimped and then dipped in a pot of molten solder. Another interesting one was terminals for power window switches. The wire cutting machine would cut, strip, apply flux, tin the wire, crimp the terminal, reflow the solder with a specially adapted spot soldering press and finally remove the flux in a solvent bath. Average production rate was around 20 pieces per minute.
TH-cam time well spent. Please do a video on ABS and traction control.
Very well done. You incorporated a lot of good pics and videos. Only missing one terminal connector, but well before your time. I had a 1908 installed elevator, that may have been the very first ring terminals. (Stakons)
To make connections of up to #6 copper wire, they took a 1-1/4" length of 1/4" copper tubing, flatten one end and drill a hole in it. Then they soldered a wire on one end and could either put the flattened end on a terminal or bolt them back-to-back in a motor box. Brilliant for 125 years ago😁
These videos are exceptionally well researched and put together.
Been WAITING WAITING on this one, thank you!!
this is the most inforamtive harness documintaion video i've seen. thank you very much for your effort in everything. i enjoyed it a lot.
This is the first time I’ve heard the notion of dielectric communicated with any intuition. Thanks!
Exceptional work here, 44 years engineering in big auto harnesses world wide you have missed one little understood design aspect of the best automotive connectors. Shortly after the auto industry designed plastic shelled dedicated connectors with "click on insert, pull to test" terminals this was upgraded to "Yoka Poke" (fool proof assembly) connectors incorporated "locking keys" that must be inserted fully home and would only go fully home only if all terminals present were seated and home to depth correctly. These keys if not fully home would not allow the connectors to be mated so insuring all connectors were either assembled correctly or open circuit, NO INTERMITTENT CONNECTIONS, intermittent connections being the worst failure of automotive wiring. These fool proofing keys often worked as secondary latching systems and were confused as such as they were so similar however this was not heir prime function. Good test systems such as shown at 14:37 would detect a key not fully home or missing thus ensuring terminals were inserted fully into housings so catch the failures at manufacture however if not detected the harness could not be connected on the production line, a worse failure but not as bad as being connected with a badly seated terminal that would pass line inspection only to go intermittent on the customer at a later date, such a failure often difficult to diagnose.
Awesome video mate, very well put together, I've been working on cars for 35 years.
Excellent overview of the industry; now you need to explain how Tesla is pushing the entire Ethernet based connection into a car
Very very good production. Thorough and brought us right up to the 21st century. Impressive
The video was very good. I only missed a little bit in the end Tesla's latest development of their patented modular wiring system to cut down on 90+% of wires
This was great production. Thanks
This was incredibly informative. Thank you!
This was great. I did not know about balanced serial communication. Now I've got something new to consider when making my wiring harness for my stuff. Great video. 😎👍
Great video for 2022 but You forgot where we are today:
Wires have been slashed in number and size by running Gigabit ethernet cabling + data CANbus to every component- all on the same 48v cable.
You can make a new video on it called "evolution of automotive wiring from 2023 on"