Automotive Wire Harness, also known as low-voltage wire, is different from ordinary household wires. Ordinary household wires are copper single-core wires with a certain hardness. The car wires are all copper multi-core flexible wires, some of which are as thin as hair, and several or even dozens of soft copper wires are wrapped in plastic insulated tubes (polyvinyl chloride), which is 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.
There are two types of systems for manufacturing automotive wiring harnesses:
1. By European and American countries, including China:
Use the IATF16949 system to control the manufacturing process.
2. Mainly in Japan:
For example, Toyota and Honda have their own systems to control the manufacturing process.
With the increase of automobile functions and the universal application of electronic control technology, there are more and more electrical parts, more and more wires, and the wire harness becomes thicker and heavier. Therefore, advanced cars have introduced CAN bus configuration, using multiplex transmission system. Compared with the traditional wiring harness, the multi-channel transmission device greatly reduces the number of wires and connectors, making wiring easier.
Automotive Wire Harness
Before arranging the wiring harness, the wiring harness diagram must be drawn in advance. The wiring harness diagram is different from the circuit schematic diagram. 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 wiring harness diagram must take into account the size and shape of each electrical component and the distance between them, and also reflect how the electrical parts are connected to each other.
After the technicians of Wire Harness Factory made the wire harness wiring board according to the wire harness diagram, the workers cut off the wire according to the provisions of the wire harness board. The main wiring harness of the vehicle is generally divided into engine (ignition, EFI, power generation, starting), instrumentation, lighting, air conditioning, auxiliary electrical appliances, etc. There are main wiring harness and branch wiring harness. A vehicle's main wiring harness has multiple branch wiring harnesses, just like tree poles and branches. The main wiring harness of the vehicle often takes the dashboard as the core part and extends forward and backward. Due to the length relationship or ease of assembly, some car wiring harnesses are divided into the front wiring harness (including instrument, engine, headlight assembly, air conditioner, battery), rear wiring harness (rear lamp assembly, license plate light, trunk light), roof Wiring harness (doors, ceiling lights, audio speakers), etc. Each end of the harness will be marked with numbers and letters 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, which is particularly useful when repairing or replacing the harness. At the same time, the color of the wire is divided into a single-color wire and a two-color wire. The purpose of the color is also specified, and it is generally a standard customized by the car manufacturer.
The wiring harness is wrapped with woven thread or plastic adhesive tape. For safety, processing and maintenance convenience, the woven thread 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 lug. The interposer is made of plastic and has plugs and sockets. The wiring harness and the wiring harness are connected with a connector, and the connection between the wiring harness and the electrical component is connected with a connector or a lug.
The automotive wiring harness also has very strict requirements on materials: including its electrical properties, material emission, temperature resistance, etc., are higher than the general wiring harness requirements, especially related to safety: such as the direction control system, brakes and other important The wiring harness of components is more stringent.