Automotive Wire Harness Error-proofing of connectors in wire harness design

The rapid development of the domestic automotive industry, the design quality requirements of the parts industry has been raised to a new level. Automotive wiring harness is an important part of the car, consisting of hundreds of connectors, in the process of assembling the wiring harness, the connector assembly process control will directly affect the quality and performance of the whole car products. This paper mainly discusses the error-proof way of connectors in automotive wiring harness design. To solve the problem from the root, so as to be able to identify the need for error-proof location, effectively eliminate product defects and improve the quality of the wiring harness.

Whether in the process of product design or manufacturing, should take into account the design of the error-proof function, and the automotive wiring harness connector error-proof design is best to consider from the design source, to solve the problem from the ground up, in order to be able to identify the need for error-proof location, the use of a variety of effective error-proof design, to avoid the product mix, omissions, misassembly and other potential risks, so as to effectively eliminate product defects, improve product quality In this way, we can effectively eliminate product defects, improve product quality, reduce production costs, and enhance the competitiveness of our products in the market.

In the design process of automotive wiring harness, especially in the instrumentation switch group, deep and shallow clutch, under seat switch group, under A pillar docking and other parts need to consider error-proof, error-proof at the same time should also consider the cost, price, delivery, maintenance convenience and production.

The significance of error-proof technology is: 

① not to pass defects to customers; 

② reduce manufacturing scrap; 

③ improve product quality; 

④ reduce manufacturing costs. 

The purpose of plug-in error-proofing is to be able to assemble connectors accurately and efficiently.

In the design of automotive wiring harness, connector error-proofing is mainly divided into the following categories: 

① structure error-proofing; 

② parts error-proofing; 

③ color error-proofing; 

④ size error-proofing; 

⑤ butt error-proofing; 

⑥ other error-proofing.

Figure 1 MG61039

Figure 2: MG611272-5

02. Component error-proof

Connector design selection:

• ① Connector design selection According to the premise of meeting the electrical end, choose a connector with a different shape, and the butt plug part of the mating end remains unchanged, and error-proofing is achieved by changing the shape of the tail, the length of the tail, the shape, etc. *

• ② Some connectors ** need to be self-locking or back cover**, in the case of the connector body remains unchanged, you can choose different back cover or self-locking, including the size of the back cover and self-locking, the direction of wire exit, guide slot, and color to prevent errors. *

  
  

Example: A model of instrument switch group idle start-stop switch and start-stop switch, the connector body is the same, the location on the body is closer, need to consider error-proof.

Connector core is the same, model number 1534120-1, also need to match the rear cover, the rear cover model number 1-1534121-1, 1-1534121-2, 1-1534121-3, 1-1534121-4, 1-1534121-5.

For error-proof consideration, different rear covers are selected, each with different colors and guide slots. Thus, the start-stop switch selects the housing model number: 1-1534121-2 (brown) (below), and the idle start-stop switch selects the housing: 1-1534121-5 (blue) (below), thus achieving an error-proof effect.

03.Color error-proofing

In the design of error-proofing applications, color error-proofing is the most intuitive and obvious, as distinguished from the color error-proofing in the component error-proofing. In the design process, consider the limitations of some parts and connector selection in the design process, can not achieve error-proofing as well as shape error-proofing, then you can also consider color error-proofing, either the connector color inconsistency, but also in the production design process to do color marking to meet the error-proofing requirements.

04. Dimensional error-proofing

Size error-proof as the name implies is that in the possible parts of the error-proof, different functions of the connector branches, through the direction of the wire, or snap and other fixed pieces of guidance to achieve the purpose of error-proof.

The ideal size error-proof is the uniqueness of the connector and the electrical end of the plug, A connector and B connector, although the same, but through the size of the error-proof, A connector can only be plugged with A electrical end, B connector can only be plugged with B electrical end.

Example illustration: The position of the deep clutch and shallow clutch harness 3D of a model is very close to each other, and the connector has chosen the same insert, i.e. deep and shallow clutch switch 3D (Fig. 4a), when it is necessary to consider the dimensional error-proof. And Figure 4b shows the deep and shallow clutch switch 2D, the long branch is the deep clutch switch, the short branch is the shallow clutch switch, and the deep clutch switch is 130 mm.

After verification, the branch of the deep clutch switch is 130 mm long, and after envelope analysis, the deep clutch switch can only be assembled on the deep clutch switch. Similarly, the shallow clutch switch is 70 mm long and can only be assembled on the shallow clutch switch. This enables unique matching by dimensional error-proofing and ensures correct operation.

05. Docking error-proof

There is a situation in the design process of automotive wiring harnesses where color error-proofing, form error-proofing, and dimensional error-proofing cannot be achieved. The connector can also be butt error-proof to avoid problems such as missed insertion, wrong insertion.

The so-called butt error-proof is to swap the butt end of the male connector and female connector to achieve the error-proof function, mainly in the non-board end of the electrical parts, especially in the A-pillar under a number of groups of butt, when similar connectors appear consistent, the need to consider butt error-proof.

Figure 5 Docking error-proof

Example Description: A model A pillar under the body to connect the instrumentation 2 groups of docking, according to the principle and the layout of space to choose 2 pairs of the exact same INLINE connector, program 1 for the initial design plan (Figure 5a), 2 green connectors are in the body, 2 red connectors are on the instrumentation, so that although the design can meet the principle, space layout and other requirements, but because it is adjacent to the location, there may be A connector plugged into the B connector on the wrong installation of the situation.

Because of the consideration of error-proofing, program 2 (Figure 5b) will be the A group connector male connector and female connector swap position, the space arrangement also meet the requirements, program 2 that is butt error-proof.

06. Other error-proofing

Harness design phase connector error-proofing there are some other ways to prevent errors. Such as:

• ① marking error-proof: in the need for error-proof connector branches to do color marking or machine labeling to distinguish; *

• ② wrapping error-proof: some parts can be wrapped in different ways to prevent errors; *

• ③ Wiring direction: According to the situation, the same connector can be designed with different wire direction; *

• ④ Fixing type: If the branch needs to be fixed, different fixing methods can be used for different branches. The connectors of the three branches A, B and C may be installed wrongly, so you can choose the fixing method on branch A as round hole, on branch B as long round hole and on branch C as key hole. *

  
  

Through the above six error-proof methods, you can effectively identify and solve the automotive wiring harness design connector some leakage, mixed insertion and other situations, so as to design a more perfect wiring harness products.

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