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Automotive Wiring Harness Production Process

16Oct
2019/10/16 16:53:59

In modern cars, there are a lot of car wiring harnesses, and the electronic control system is closely related to the wire harness. Someone once used an image metaphor: If the functions of the microcomputer, the sensor and the actuator are compared to the human body, it can be said that the microcomputer is equivalent to the human brain, the sensor is equivalent to the sensory organ, and the actuator is equivalent to the moving organ, then the harness is the nerve and Blood vessels. So what is the car harness? What is its design process? We as a Wire Harness Manufacturer to give you a professional explanation.


The car wiring harness is the main body of the car circuit, and there is no car circuit without the wire harness. The wire harness refers to a component in which a contact terminal (connector) made of a copper material is crimped to a wire and cable, and an external insulator or a metal case is externally molded, and the wire harness is bundled to form a connection circuit. The wire harness industry chain includes wire and cable, connectors, processing equipment, wire harness manufacturing and downstream applications. Wire harness applications are widely used in automotive, household appliances, computer and communication equipment, various electronic instrumentation, etc. The general shape is H-shaped. Automotive wiring harness requirements are also very strict: including its electrical performance, material sporadic, temperature resistance, etc., are higher than the general wire harness requirements, especially related to safety: such as directional control systems, brakes, etc. The wiring harness of the components is more demanding.




Automotive Wire Harness


The Automotive Wire Harness is functionally divided into a power line carrying electric power for driving an actuator (actuator) and a signal line for transmitting a sensor input command. The power line is a thick electric wire that carries a large current, and the signal line is a thin electric wire (optical fiber communication) that does not carry electric power; for example, the cross-sectional area of a wire for a signal circuit is 0.3, 0.5 mm2. The cross-sectional area of the wire for the motor and the actuator is 0.85 and 1.25 mm2, and the cross-sectional area of the power supply circuit is 2, 3, and 5 mm2; and the special circuit (starter, alternator, engine grounding wire, etc.) has 8. 10, 15, 20mm2 different specifications. The larger the cross-sectional area of the wire, the larger the current capacity. The choice of wires, in addition to considering the electrical performance, is also subject to the physical properties of the vehicle, so the choice is very wide. For example, a frequently-switched door on a taxi and wires that span the body should be constructed of wires that exhibit good flexing performance. Wires used in places where the temperature is high are generally made of vinyl chloride or polyethylene coated with good insulation and heat resistance. In recent years, electromagnetic shielding lines used in weak signal circuits have also increased.



The role of the automotive wiring harness in the vehicle is to transfer or exchange the power signal or data signal of the electrical system to realize the functions and requirements of the electrical system. The following is a brief discussion of the specific process of car wiring harness design and manufacturing.


First, the electrical layout engineer first provides the functions, electrical loads and related special requirements of the vehicle electrical system. The state of the electrical device, the mounting location, the form in which the harness and the electrical device are docked.

Second, according to the electrical functions and requirements provided by the electrical layout engineer, the electrical schematic and circuit diagram of the vehicle can be drawn.

Third, according to the electrical principle circle for each electrical subsystem and circuit energy distribution, including the grounding of the power supply, and the distribution of grounding points.

Fourth, according to the distribution of electrical components of each subsystem, determine the wiring form of the harness, the electrical components connected to each harness and the direction on the vehicle; determine the external protection form of the harness and the protection of the via; determine the fuse according to the electrical load Or circuit breaker; then determine the wire diameter of the wire according to the amount of the fuse or the circuit breaker; according to the function of the electrical device, determine the wire color of the wire according to relevant standards; determine the terminal and the wire to be connected to the wire harness according to the connector of the electrical device itself Set of models.

Fifth, draw a two-dimensional wire harness diagram and a three-dimensional wire harness layout diagram.

Sixth, according to the approved three-dimensional wire harness layout diagram, the two-dimensional wire harness diagram is checked, and the two-dimensional wire harness diagram can be printed accurately. After being approved, it can be trial-produced and produced according to the wire harness diagram.


The above is about the introduction of the car wiring harness, if you have this need, you can contact us. Our company produces all kinds of High Quality Wire Harnesses, and we are sure to satisfy you.

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