We all know that automobiles are precision instruments, especially today when automobiles are becoming increasingly intelligent. Automobile wiring harnesses are the key to the entire vehicle's electrical system. It is precisely because of the connection of the car's wire harness that the electronic instruments on the car can operate normally and realize various intelligent functions. However, the wire harness is a multi-component bundled product. Its detection components include wire detection, sheath detection, terminal detection, fastening tape detection, heat shrink tube detection, sub-sensitive tape detection, copper braided wire detection, and sealing ring detection. and many more. Moreover, the materials involved in testing also include rubber material testing, plastic material testing, metal material testing and other fields. This poses a challenge to the inspection of automotive wiring harnesses.
Cable and wire testing, as an advantageous testing service area of the laboratory, has always been our key research object. The performance analysis of each component of the automotive wiring harness is also our mature service testing product. With reference to QC/T 29106-2014, automotive wire harness inspection items include appearance inspection, wire harness size measurement, terminal and wire connection, contact inspection, rubber waterproof performance, electrical performance, temperature resistance, humidity resistance, and Vibration performance, salt spray resistance, chemical resistance, etc. Of course, these testing items will be subdivided into many specific items.
Take the terminal and wire connection detection as an example. First, we need to detect the crimp connection between the terminal and the wire, conductor connection, insulation layer connection, insulation crimping with sealing plug, connection ribs, connection strength, voltage drop, soldering connection, etc. And other items. Among them, the insulation layer connection can be detected by a bending test, and the connection strength can be reflected by measuring the minimum tension value.
For the measurement of automobile wire harness size, the instruments needed are steel tape measure, professional inspection tool, and protractor. The tests involved are terminal and wire connection test, insulation lamination bending test, conductor crimping zone cross-section test, connection strength test, voltage drop test, contact test, wet zone contact immersion test, contact tearing force test , Rubber parts waterproof performance test, electrical performance testing test, and related weather resistance test (chemical resistance, low temperature resistance, high temperature resistance, temperature change resistance, temperature and humidity change resistance), vibration resistance test, etc.
Therefore, the automotive wiring harness testing items summarized by the testing engineers mainly include electrical performance. We can test its rated voltage, rated current, temperature rise, contact resistance, insulation resistance, dielectric strength, current cycle resistance and other indicators. Mechanical properties we can detect the insertion force, pull-out force, terminal retention force, hook strength, unlocking force, mechanical impact resistance and other indicators. Environmental performance can detect air tightness, water resistance, salt spray resistance, heat aging, oil resistance, and so on.
In fact, no matter what, the inspection of automobile wiring harness should be determined according to the needs of customers. Some manufacturers will test the rapid current resistance, bending resistance, cold resistance, acid resistance, and ozone resistance of the wiring harness sub-components. This is also based on the consideration of the working environment of its product application. There are also some unnecessary test items removed from cost considerations. All this requires us to make a scientific and reasonable testing plan. have also been removed from cost considerations. All this requires us to make a scientific and reasonable testing plan.