Carries power from the battery and PDM to every load, and carries the control signals.
Combined with the busbar harness on CR22, which removed the weight of running separate 12 V and ground harnesses.
No part-specific design process is documented. The Electrical Harness subsystem design process applies: 1. Collect the sensor list and the datalogger assignment for each sensor. 2. Draw the harness in RapidHarness: main connectors, sensor connectors, connections, then bundles and split points. 3. Order wire early. BMRSWired lead time has run 2 weeks to 3 months and is the single highest-impact long lead item. 4. Cut and crimp terminals, assemble connectors, build service loops. 5. Twist the harness, cover with DR-25 heat shrink, test fit on the frame, then install and recover transition boots and connector boots.
Designed in RapidHarness, then cut, crimped, assembled with service loops, twisted, covered in DR-25 and test fitted on the frame before boots are installed.
Includes the 8 AWG charging system wiring and 12 AWG on the REC+ line.
CR22 Issue Log, 2023-12-03, Electrical. Failed stator-to-rectifier crimps stopped the car charging and killed three batteries in a drive day. The CR22 charging circuit had a separate sizing failure: the REC+ wire was originally 16 AWG and could not carry enough current over an endurance. Rectifier current dropped off significantly at the end of the Kennesaw endurance as the wire heated up. Swapping to 12 AWG fixed it, confirmed on a post-Kennesaw mock endurance. The team's Car Wiring Lessons Learned document records the recurring wiring failures directly: wires melting where they are routed near the exhaust without heat protection, grounds corroding or being damaged at the frame so an unexplainable fault turns out to be a ground above 5 ohms, paint left on frame grounding spots, and the engine being assumed grounded through its mounting bolts when paint or corrosion prevents it.
REC+ wire increased from 16 AWG to 12 AWG. Splices grouped in one area for serviceability, and boots added to the back of connectors to protect the wires, which had not been done on previous cars.
Nothing in CrimsonStorage covers these yet.