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What are the Automotive Wiring Harness Production Processes?

20Mar
2020/03/20 09:03:25

Automotive wires are also called low-voltage wires, which are different from ordinary household wires. The ordinary household wire is a copper single core wire, which has a certain hardness. Automotive wires are copper multi-core flexible cords, some of which are as thin as hair, and several or even dozens of flexible copper wires are wrapped in plastic insulated tubes (polyvinyl chloride), which are soft and not easy to break. Due to the particularity of the automotive industry, the manufacturing process of automotive wiring harnesses is also more special than other ordinary wiring harnesses. Today Wire Harness Factory will tell you about the process of manufacturing automotive wiring harnesses.


Before you arrange the wiring harness, you must draw a wiring harness diagram in advance. The wiring harness diagram is different from the circuit schematic. The circuit schematic is an image that expresses the relationship between various electrical parts. It does not reflect how electrical parts are connected to each other, and is not affected by the size and shape of each electrical component and the distance between them. The wire harness diagram must take into account the size and shape of each electrical component and the distance between them, and it must also reflect how the electrical components are connected to each other.


After the technician at the wiring harness factory made the wiring harness wiring board according to the wiring diagram, the workers cut the wiring according to the rules of the wiring board. The vehicle main wiring harness is generally divided into the engine (ignition, EFI, power generation, starting), instrumentation, lighting, air conditioning, auxiliary appliances and other parts, there are main wiring harness and branch wiring harness. A vehicle main harness has multiple branch harnesses, just like tree poles and branches. The main wiring harness of the whole vehicle often uses the dashboard as the core part and extends forward and backward. For reasons of length or ease of assembly, some automotive wiring harnesses are divided into front wiring harnesses (including gauges, engines, front light assemblies, air conditioners, batteries), rear wiring harnesses (tail light assembly, license plate lights, trunk lights), and roof Harnesses (doors, ceiling lights, audio speakers), etc. Each end of the wire harness is marked with a number and letter to indicate the connection object of the wire. The operator sees that the mark can be correctly connected to the corresponding wire and electrical device. This is particularly useful when repairing or replacing the wire harness. At the same time, the color of the wire is divided into single-color and double-color, and the use of the color is also specified, which is generally a standard customized by the car factory.


Automotive Wire Harness is wrapped with woven wire or plastic adhesive tape. For safety, processing and maintenance convenience, woven wire wrapping has been eliminated and is now wrapped with adhesive plastic tape. The connection between the wiring harness and the wiring harness, and between the wiring harness and the electrical parts adopts a connector or a wire lug. The connector is made of plastic and has a plug and a socket. The wire harness and the wire harness are connected by a connector, and the connection between the wire harness and the electrical parts is by a connector or a wire lug.


Automotive wiring harness also has strict requirements on materials:

Including its electrical properties, material emission, temperature resistance, etc., are higher than general wiring harness requirements, especially when it comes to safety: wiring harnesses for important components such as direction control systems and brakes have stricter requirements.

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