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Automotive imaging systems—such as ADAS (Advanced Driver Assistance Systems) cameras, backup (rear) cameras, and 360° surround-view cameras—rely on custom wire harnesses to carry power and high-speed video data. These harnesses must ensure reliable data flow and power delivery from each sensor to the ECU under vehicle conditions.
In practice, this means using cables (such as coaxial, shielded LVDS ribbon, or twisted-pair) that are specifically chosen for their data rate and distance, and routing them through tight spaces without signal loss.
Harsh Conditions & Materials
Automotive imaging systems are exposed to extreme environments, including engine heat and exhaust cooling, road vibration, moisture (such as rain and washes), and electrical noise. High-flex copper conductors and supple insulation (TPE, silicone) are used, allowing the wires to flex repeatedly without cracking. Strain-relief features, such as corrugated conduit or molded grommets, prevent chafing. Overmolding the cable ends in rubbery jackets helps block shock and seal out contaminants. Flexible shielding (braided copper or foil) is wrapped around camera data lines to suppress EMI and preserve clean video signals.
In short, each harness is constructed from high-flex materials and multi-layer jackets to withstand constant bending, temperature fluctuations, dust, and vibration.
EMI Shielding and Signal Integrity
Automotive cameras generate large data streams that demand high signal integrity. EMI shielding is crucial in preventing noise from other vehicle systems. Harness bundles often include 360° braided copper shields or foil wrap around the cable cores. This shielding is grounded at one end to block interference from the engine, alternator, and wireless antennas. In many cases, the entire harness is routed inside a protective conduit or is overmolded at connection points for extra EMI resistance.
For example, industrial OEM designs note that integrated foil/braid shielding creates a rugged bundle that survives harsh conditions. In automotive imaging applications, such shielding ensures that high-speed video links (e.g., LVDS, Ethernet) remain free from noise.
Connector and Cable Options
Connectors for camera harnesses must lock securely and be waterproof to ensure reliable operation. Standard automotive camera connectors include sealed coaxial plugs (e.g., SMB, FAKRA, Mini-FAKRA) and multi-pin sealed housings (e.g., Molex Mini50, TE/Delphi micro-locks). These connectors are designed for harsh environments—they resist moisture, dust, and vibration while providing reliable mating.
For example, Molex touts camera connector systems that “must perform reliably in high-vibration environments and extreme temperature shifts while minimizing EMI”. In practice, an ADAS forward-camera harness typically utilizes a shielded twisted-pair cable with a locking board-to-wire connector.
- ADAS camera harnesses: High-speed LVDS or SerDes links, shielded twisted-pair or coax, IP-rated locking connectors.
- Backup/reverse camera harnesses: Power and composite/HD video lines, often 4-pin R/C or FAKRA coax, with a flexible jacket and duty-cycle design for tailgate movement.
- 360° surround-view harnesses: Multiple channels (front/rear/side cameras), usually a mix of coax and ethernet/LVDS, with bundled shielding and strain relief for each camera run.
Durability and Flexibility
Wiring for imaging systems may be routed through doors, hoods, or trunk lids, requiring constant flexing. Harness assemblies therefore utilize fine-stranded, high-flex copper wires and supple sheathing, ensuring that repeated bending does not fatigue the conductors. Flexible conduit (also known as corrugated tubing) or braided jackets are often added for enhanced abrasion resistance in moving parts. For example, the conduit shown below protects wires from rubbing on metal edges. Weatherproof boots and overmolded ends give strain relief at connectors.
In short, the harness design blends high-flex materials with robust security. OEM-grade harnesses are routinely subjected to tens of thousands of flex cycles and vibration tests to verify their durability.
Environmental Sealing
Automotive camera harnesses must also keep out water and dust. This means using IP-rated seals and gaskets on connectors, plus robust jacketing (PVC, UV-resistant TPE, or polyurethane). The entire assembly may be designed to withstand engine under-hood heat or sub-zero cold. Standard automotive criteria (e.g., -40°C to +105°C) apply. In practice, manufacturers specify high-temperature insulation (PVC is avoided near engines; TPE/silicone are used instead) and waterproof connectors (bussed pins, O-rings, gel fills). As one authority notes, robust automotive harnesses are tested for IP67 or even IP69K ratings to ensure moisture ingress is prevented.
Comparing Harness Specs for Imaging Systems
| Specification | ADAS Camera Harness | Backup Camera Harness | 360° Surround View Harness |
|---|---|---|---|
| Data Interface | High-speed LVDS / SerDes (multi-gigabit) | Analog (RCA) or low-rate LVDS | Mixed LVDS/analog / Ethernet |
| Cable Type | Shielded twisted-pair or coax (differential pairs) | 4-pin power + coaxial video cable | Bundle of shielded cables (coax + twisted-pair) |
| Connector Type | Sealed multi-pin (Molex/Delphi/TE) or coax (FAKRA) | Waterproof 4-pin plug or FAKRA coax | Multiple FAKRA/Rosenberger connectors |
| Shielding | 360° foil braid shielding around all data wires | Braided copper on video line | Full-bundle braid + individual shields |
| Flex Requirement | Moderate (fixed mount under windshield) | Very high (hinged tailgate, doors) | High (several cameras on moving parts) |
| Ingress Protection | Typically IP67 at camera connector | IP68 (under-body exposure) | IP67/68 for all camera modules |
| Typical Length | ~1–3 meters | ~1–2 meters (short feed to head unit) | Varies: 4 cables 1–4m each |
The table above highlights the distinct emphases of each imaging application. ADAS cameras focus on data speed and EMI protection, while backup camera harnesses prioritize extreme flexibility and sealing. All imaging harnesses, however, share features like braided EMI shields and rugged connectors to meet automotive standards.
OEM Custom Harness Solutions
For automotive OEMs, custom harness design is essential. Engineers work closely with manufacturers to specify wire gauges, shielding layers, and connector styles that match each camera system. All custom harnesses are validated against industry standards (IPC/WHMA-A-620, IATF 16949) and tested 100% for continuity, insulation, and environmental stress. Modern tooling (computer-aided harness simulation) helps predict impedance and crosstalk for high-speed camera links, ensuring the cable assembly will meet performance requirements in the actual vehicle.
As an experienced cable manufacturer, we at Romtronic maintain in-house engineering, prototyping, and full production capabilities—allowing us to tailor each wiring harness precisely to your OEM application. We select the right conductors and insulations for flex life, add EMI shielding and overmolds for strain relief, and integrate sealed connectors to ensure long-term reliability.
Conclusion: In-House Production by Romtronic
Custom wire harnesses for imaging systems demand both precision and durability. When OEMs partner with Romtronic, you gain direct access to our in-house design and manufacturing expertise. We work closely with your engineering teams on EMI strategy, connector selection, and material choices—then build and test every harness in our own facility. The result is a high-performance, purpose-built cable assembly that ensures dependable camera functionality, even under the toughest automotive conditions.
Sam Wu is the Marketing Manager at Romtronic, holding a degree in Mechatronics. With 12 years of experience in sales within the electronic wiring harness industry, he manages marketing efforts across Europe. An expert in cable assembly, wiring harnesses, and advanced connectivity solutions, Sam simplifies complex technologies, offering clear, actionable advice to help you confidently navigate your electrical projects.
