What is Automotive Wiring Harness
Automotive wiring harness is the main body of the network of automotive circuits, there is no wiring harness there is no automotive circuits. Harness refers to the copper punching and made of contact parts terminals (connectors) and wire and cable crimping, and then outside the plastic pressure insulator or additional metal shells, etc., to the harness bundle formed by connecting the circuit components. Wiring harness industry chain including wire and cable, connectors, processing equipment, wiring harness manufacturing and downstream application industry, wiring harness applications are very wide, available in automobiles, household appliances, computers and communication equipment, various electronic instruments and meters, etc., the body wiring harness connects the entire body, the general shape of the H-shaped.
Main specifications and performance requirements for automotive wiring harnesses
Cross-sectional area of the wire
According to the size of the load current of the electrical equipment to choose the cross-sectional area of the wire, the general principle of long working hours of electrical equipment can be used to select the actual flow of 60% of the wire, a short period of time to select the actual flow of the electrical equipment between 60% -100% of the wire; at the same time, should also take into account the voltage drop in the circuit and the conductor heat and so on, in order to avoid affecting the electrical performance of the electrical equipment and the permissible temperature of the conductor; in order to To ensure a certain degree of mechanical strength, the general cross-sectional area of low-voltage wire is not less than 1.0mm².
The color of the conductor car circuit with color and number characteristics. With the increase in automotive electrical equipment, the number of wires is also increasing, in order to facilitate the identification and maintenance of automotive electrical equipment, automotive circuits in the low-voltage line is usually made up of different colors, and in the automotive electrical wiring diagrams with the color of the letter code marked out. In the automotive circuit diagrams are usually marked out the color code of the wire (with one or two letters), the color of the wire on the car is generally different, commonly used single-color and two-color two selection principles. Such as: red (R), black (B), white (W), green (G), yellow (Y), black and white (BW), red and yellow (RY). Among them, the two-color wire in the first one is the main color, the latter one is the secondary color. Physical properties of the wire (1) winding performance, the door and across the body between the wire should be composed of good winding performance of the wire. (2) High-temperature resistance performance, the wire used in high-temperature parts is generally insulated and heat-resistant good vinyl chloride, polyethylene-coated wire. (3) Shielding performance, in recent years, weak signal circuits using electromagnetic shielding wire is also increasing. Wiring harness wra pping (1) cable half-stacked wrapping method, coated with insulating varnish and drying to increase the strength of the cable and insulation properties. (2) new wire harness, local plastic wrapping and put into the side cut plastic bellows, so that its strength is higher, better protection performance, find line faults more convenient.
Production process for wire harnesses
The first station in wire harness production is the wire opening process. The accuracy of the open wire process is directly related to the entire production schedule, once the error is particularly short open wire size, will lead to all the workstation rework, time-consuming and laborious impact on production efficiency. So in the preparation of the open wire process must be based on the requirements of the drawings to reasonably determine the size of the wire open wire, stripping head size.
After the opening of the second station is the crimping process, according to the drawing requirements of the terminal type to determine the crimping parameters, the production of crimping instructions, for special requirements need to be specified in the process documentation and training of operators. For example: some wires need to pass through the sheath before crimping, it needs to be pre-installed wire and then return from the pre-installation station and then crimp; there are also puncture crimping with a special crimping tool, this crimping method has good electrical contact properties.
Then there is the pre-installation process, first of all, to prepare the pre-installation process operating instructions, in order to improve the efficiency of the total assembly, the complexity of the wiring harness should be set up to pre-installation stations, pre-installation process is reasonable or not directly affects the efficiency of the total assembly also reflects the technical level of a craftsperson high and low. If the pre-assembly part of the assembly is less or assembly of the wire path is not reasonable will increase the total assembly staff workload, slowing down the speed of the assembly line, so the process staff should often stay on site to constantly summarize.
The last step is the final assembly process. According to the product development department to design the assembly board, design equipment, material box specifications and size and will be assembled all the sheaths and accessories of the number affixed to the material box in order to improve the assembly efficiency. Preparation of each station assembly content and requirements, balancing the entire assembly station to prevent one point of workload is too large, pulling down the speed of the entire assembly line.
Components of a wire harness
An automotive wiring harness consists of wires, terminals, coverings, connectors and other parts.
Wire
wire is the main component of the wiring harness, usually called the wire, is the main part of the wiring harness, its role is mainly to carry the current required by the load. The important parameter of the wire is the current-carrying capacity, which is affected by the wire diameter (cross-sectional area of the wire conductor), the length of the wire, the resistivity of the conductor and the ambient temperature.
Connectors are also called connectors, CONNECTOR, or plugs.
Connectors are indispensable components for connecting wiring harnesses to other electrical equipment, and are divided into wiring harness end connectors and electrical end connectors. We often hear the male connector (referred to as male) and female connector (referred to as female), where the male terminal where the connector is called the male connector, the female terminal where the connector is called the female connector, we are usually the female connector at the end of the wiring harness.
Connectors can be divided into two categories: waterproof and non-waterproof. At the beginning of the design, according to the size of each PIN pin to carry the current, select different widths of PIN pins, and then formed in the connector to accommodate different PIN pin chamber, thus forming a housing to accommodate multiple PIN.
(1) CPA-plastic shell secondary locking mechanism ConnectorPositionAssurance: its function is to ensure that the plastic shell and electrical interface assembly in place after the primary locking mechanism of the carabiner will not be easily withdrawn, due to the special nature of its function, so the CPA in the design of the workers must ensure that the maneuverability and recognizability, which requires the CPA in the plastic shell must be independent of the mechanism and also must have special color marking.
(2) Waterproof sealing ring: There are 2 kinds of waterproof sealing mechanism, one is used for sealing between molded case and molded case, and the other is used for sealing terminal lead wires.
(3) TPA-terminal secondary locking structure TerminalPositionAssurance: not all terminals need a secondary locking structure, VW requirements is the terminal width of 2.8mm (including 2.8) or less should be used TPA, in order to ensure that the wiring harness factory workers to facilitate the installation of the color of the TPA is also required to be recognizable, and the assembly of a clear sense of touch. In order to ensure that the plastic shell in the process of transportation to the wire harness factory TPA will not automatically enter the lock position, anti-locking effect of the mechanism in the TPA is necessary.
Wiring harness wraps
The main role of the harness wraps is to protect the wiring harness, according to the different materials of the wraps, the types of wraps are mainly bellows, PVC tape, cloth-based tape, flannel tape, sponge tape and aluminum foil tape. Because of the different materials, the material characteristics of different wraps are not consistent, accordingly, its application conditions and methods in the harness assembly are not consistent, the specific selection should be based on the specific use of the harness environment and its abrasion resistance, heat resistance.
Wiring harness fixtures
Unlike other automotive parts, wiring harness is a flexible part, the wiring harness can not be sent in accordance with the established shape of the sample, so in order to constrain the wiring harness in the vehicle layout path, you need to add additional parts to the wiring harness to be fixed, these additional parts is the wiring harness fixtures, which play a role in fixing the harness and constraints on the layout path of the wiring harness. Wiring harness fixtures are: ties, clips, rubber sheaths, harness brackets, etc., according to the different installation environments of the wiring harness, such as the wiring harness installation space, the temperature requirements, waterproofing requirements, the form and material of each wiring harness fixture is not the same, even so, the wiring harness fixtures are also presenting a trend of standardization, and is also the wiring harness platform selection of one of the easier to realize the parts.
Harness Accessories
Harness accessories are other smaller products on the harness assembly, such as product labels fuse clips on the harness assembly.
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