What are the wire harness product design process and specifications? How to design wire harness products?

The design process of wire harness products usually includes the following stages, and need to follow some relevant norms and standards: Determine the needs: Clearly the use of wire harness products, application areas, electrical load requirements, environmental conditions. Understand the wiring harness connected to the various electrical components and signal transmission requirements. Harness design: according to the needs of the overall design of the harness. Including the layout, size, wire selection, connector selection, insulation material selection, wiring path, etc.. Ensure that the harness can meet the requirements of electrical performance, mechanical strength and environmental adaptability. Electrical performance calculation: According to the current, voltage and signal requirements of the harness, calculate the cross-sectional area, resistance, voltage drop and other parameters of the wire. Ensure that the wire is thick enough to meet the electrical performance requirements. Material Selection: Select suitable wires, insulation materials, sheath materials and connectors. Consider the material's heat resistance, abrasion resistance, flame retardancy, corrosion resistance and other characteristics. Wiring path design: Determine the wiring path of the harness according to the structure and layout of the vehicle or equipment. Avoid interference with other components to ensure the safety and reliability of the wiring harness. Connector design: According to the connection requirements of the wiring harness, select the appropriate connector, and design the wiring mode and plugging reliability of the connector. Insulation and protection measures: Ensure that the wiring harness has sufficient insulation to prevent electrical shorts and leakage. Also consider adding protective sleeves, sheaths and other materials to enhance the durability and abrasion resistance of the wire harness. Harness fixing and support: Design harness brackets, clips and fixtures to ensure that the harness is securely fixed and supported during use to prevent loosening and vibration. Marking and labeling: Appropriately mark and label wire harnesses to facilitate installation, maintenance and troubleshooting. Verification and testing: Verify and test the designed wiring harnesses, including electrical performance testing, connectivity testing, flame retardant testing, etc. Ensure that the wiring harness meets the design requirements and relevant standards. When designing a wiring harness product, it is also necessary to follow a number of related specifications and standards, such as IPC/WHMA-A-620, UL standards, ISO standards, industry-specific standards, and so on. These codes and standards provide guidelines for harness design, manufacturing and testing to ensure the quality, reliability and safety of the harness. Finally, designing a wiring harness product requires comprehensive consideration of electrical performance, mechanical strength, environmental suitability, reliability and safety. It is recommended that you work with a specialized harness manufacturer, engineer or electrical expert for more comprehensive guidance and support during the design process.

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