Wire Harness, also known as low-voltage wires, 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 soft wires, some of which are as thin as a hair, and several or even dozens of soft copper wires are wrapped with plastic insulating 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 common wiring harnesses. Systems for manufacturing automotive wiring harnesses are broadly divided into two categories: 1. Divided by European and American regions, including China: TS16949 system is used to control the manufacturing process.
2. Japan: Like Toyota and Honda, they have their own system to control the manufacturing process. With the increase of automobile functions and the wide application of electronic control technology, there will be more and more electrical components, more and more wires, and the Wiring Harness will become thicker and heavier. Therefore, advanced automobiles have introduced the CAN bus configuration and adopted a multiplex transmission system. Compared with traditional wiring harnesses, multiplexers greatly reduce the number of wires and Connectors, making wiring easier.
The common specifications of wire rods in commonly used Automotive Wire Harness include nominal cross-sectional areas of 0.5, 0.75, 1.0, 1.5, 2.0, 2.5, 4.0, 6.0, etc. 2.0, 2.5, 4.0, 6.0 square millimeters), each has a allowable load current value, which is used for wires of different electrical and electrical equipment. Taking the wiring harness of the whole vehicle as an example, the 0.5 gauge line is suitable for instrument lights, indicator lights, door lights, dome lights, etc.; the 0.75 gauge line is suitable for license plate lights, front and rear small lights, brake lights, etc.; lights, etc.; 1.5 gauge line is suitable for headlights , speakers, etc.; generator armature wires, ground wires and other main power lines need 2.5 to 4 square millimeters of wire. This is only for ordinary cars, the key depends on the large current value of the load. For example, the ground wire of the battery and the positive wire of the power supply are dedicated wires used separately. Their wire diameter is relatively large, at least a dozen square millimeters or more, these "jumbo" wires will not be woven into the main wiring harness. Before laying out the wiring harness, the wiring harness diagram should be drawn in advance. A wiring harness diagram is different from a circuit schematic diagram. A circuit schematic is an image that represents the relationship between various electrical components. It does not reflect how electrical components are connected to each other, nor is it 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 components are connected. After the technicians in the wiring harness factory make the wiring harness wiring board according to the wiring harness diagram, the workers cut and wire according to the regulations of the wiring 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., and is divided into main wiring harness and branch wiring harness. The main vehicle wiring harness has multiple branching harnesses, like tree trunks and branches.
The main wiring harness of the whole vehicle usually takes the instrument panel as the core part and extends forward and backward. Due to the length relationship or the convenience of assembly, some automotive wiring harnesses are divided into front wiring harness (including instrument, engine, headlight assembly, air conditioner, battery), rear wiring harness (tail light assembly, license plate light, trunk light), roof wiring harness (door , dome lights, audio speakers) and other wire harnesses are marked with numbers and letters at each end to indicate who the wires are connected to. Operators can see the markings to properly connect to the corresponding wires and electrical equipment, which is especially useful when repairing or replacing wiring harnesses.
At the same time, the color of the wire is divided into single-color wire and double-color wire, and the use of the color is also regulated, which is generally the standard customized by the car factory. my country's industry standards only stipulate the main color. For example, it is stipulated that the single black color is dedicated to the ground wire, and the red single color is the power wire, which cannot be confused. The harness is wrapped with braided wire or plastic tape. For safety, ease of processing and maintenance, the braided wire wrap has been removed and is now wrapped with sticky plastic tape. Connectors or lugs are used for the connection between the wire harness and the wire harness and between the wire harness and the electrical components. Connectors are made of plastic and are divided into plugs and sockets. The wire harness is connected to the wire harness through a connector, and the connection between the wire harness and the electrical component is through a connector or a lug.
Materials Automotive wiring harnesses also have very strict requirements on materials: including their electrical properties, material emissions, temperature resistance, etc., are higher than the requirements of general wiring harnesses, especially in terms of safety: such as directional control systems, brakes, etc. There are more stringent requirements for the wiring harness of important components. If you need Custom Cable Assembly, you can contact us, we have many years of experience.
