Common faults in the Electric Wire Harness are: poor contact of the connector, short circuit between the wires, open circuit, grounding, and the like.
There are several reasons for this:
1) Natural damage
The use of the wire harness exceeds the service life, causing the wire to age, the insulation layer to rupture, and the mechanical strength to drop remarkably, causing a short circuit between the wires, an open circuit, a grounding, etc., causing the wire harness to burn out. The wire terminal is oxidized and deformed, resulting in poor contact, etc., which may cause the electrical equipment to malfunction.
2) Damage to the wiring harness due to malfunction of electrical equipment
When electrical equipment is overloaded, short-circuited, grounded, etc., it may cause damage to the wiring harness.
3) Human failure
When assembling or repairing auto parts, the metal object crushes the electric wire bundle, causing the electric wire bundle insulation layer to rupture; the electric wire bundle is improperly positioned; the lead position of the electrical equipment is connected incorrectly; the positive and negative electric wires of the battery are reversed; when the maintenance circuit is faulty, chaos Connecting and chaosing wire harness wires can cause abnormal operation of electrical equipment and even burn out the wiring harness.
Electric Wire Harness
So how should we detect and judge? The Automotive Wire Harness manufacturer will come to tell you.
1) Detection and judgment of wire harness burnout failure
The burnt wire bundles are all suddenly occurring, and the burning speed is very fast. In the burned circuit, there is generally no safety device. The rule of burning the electric wire bundle is: in the circuit of the power supply system, which point is grounded, where the electric wire bundle is burned, where the burnt and the intact part are at the junction, it can be considered that the electric wire is grounded; if the electric wire bundle is burned out When the wiring to an electrical equipment indicates that the electrical equipment is faulty.
2) Detection and judgment of short circuit, open circuit and bad contact between lines
The wire bundle is externally squeezed and impacted, causing damage to the wire insulation in the wire bundle, causing a short circuit between the wires, causing some electrical equipment to lose control and the fuse to blow. When judging, the electrical harness connector at both ends of the electrical equipment and the control switch can be disconnected, and the short circuit of the line can be detected by the electric meter or the test light. Wire breakage failure, in addition to the obvious fracture phenomenon, common faults occur mostly between the wire and the wire terminal. After some wires are broken, the outer insulation layer and the wire terminals are intact, but the inner core wire and the wire terminal of the wire are broken. When judging, the tensile test can be performed on the conductive wire and the wire terminal of the suspected open circuit. During the tensile test, if the wire insulation layer is gradually tapered, it can be confirmed that the wire has been broken. Poor line contact, faults occur in the connector. When a fault occurs, it may cause the electrical equipment to malfunction. When judging, the power of the electrical device is turned on, and the relevant connector of the electrical device is touched or pulled. When a connector is touched, the operation of the electrical device is normal and abnormal, indicating that the connector is abnormal. malfunction.
3) Inspection of appearance
a new wiring harness model should be consistent with the original model, the wire terminal and the wire are connected reliably, and the connector and the wire can be pulled by hand to loosen or fall off.
b Compare the new wiring harness with the original wiring harness. For example, the size of the wiring harness, the wire terminal fittings, and the color of the wires should be basically the same. For doubts, use a multimeter to test and confirm that the wiring harness is intact before it can be replaced. The connectors, plugs, and sockets of each electrical device shall correspond to the sockets and plugs on the wiring harness. After connecting the connecting wires to the electrical equipment, leave a certain margin. The wires should not be pulled too tight or placed too loose.
The above is the solution to the failure of the wiring harness, I hope to help everyone. In addition, if you are interested in wiring harnesses, automotive wiring harnesses, Wire and Cable Assemblies, you can contact us and welcome everyone to come and buy.