Design specifications for electrical and electronic wiring harnesses

As people's safety, comfort and economic requirements for electronic appliances is becoming more and more high, electronic appliances on the configuration of electrical appliances, functionality is also more and more, so connecting the various electrical parts of the wiring harness is also more and more complex, and become a contemporary electronic appliances failures of multiple links, but also in the design of electronic appliances and manufacturing by more and more attention. The following is a brief description of the design process of electronic electrical wiring harness.

Schematic Design and Calculation1.1 Draw the electrical schematic diagram according to the electrical configuration and technical requirements required by the Electrical Design Task Book.1.2 Determine the capacity of the insurance and the size of the wire diameter according to the power of each electrical appliance, and at the same time allocate the load to each electrical subsystem to determine the capacity of the total insurance.1.3 Calculate the diameter of the conductor wire: according to the formula (see figure) in which: I --- current, A; P --- power of electrical parts, W; U --- voltage, V; A --- current, A; P --- power of electrical parts, W; U --- voltage, V; A --- wire diameter, mm2; ρ --- copper resistivity (about 0.0185Ωmm2/m); L = wire length, m; Ud --- allowable voltage drop loss. Also consider the following cases: a. The wire is too long can be appropriate to enlarge the wire diameter; b. The wire is connected to the electrical appliances after transferring through a number of plugs, consider the terminal voltage drop is larger, can be appropriate to enlarge the diameter of the wire. 1.4 Different forms of conductors have different permissible current and line voltage drop. Drawing three-dimensional wiring diagram 2.1 According to the location of each electrical device is different, to determine the form of three-dimensional wiring, the current international common wiring form is generally E-type and H-type; 2.2 simulation simulation of different areas of the wire harness diameter; 2.3 consider the harness over the hole sealing and protection. 2.4 harness of the fixed holes and fixing the form to determine the 2.5 Theoretically speaking, a wire harness to connect all the electrical components is **** Reasonable, but the actual loading is simply not doable, so the harness should be reasonable block, in the case of convenient assembly, try to use the systematic design. 2.6 Hitch design in the harness design is very important, otherwise it will cause signal interference, affecting the realization of the function of some electrical appliances; according to the different models of the design of a number of grounding points, the hitch should be designed to meet the following points: a. Weak signal sensors should be individually and near the iron, to ensure the normal transmission of signals; b. Each ECU should be a separate iron, to prevent interference; c. Negative battery iron and engine, transmission iron should be carefully considered. Design 2D wiring harness diagram 3.1 Distribution box (insurance and relay) is the core of the whole vehicle electrical, play: distribution of loads, centralized power supply, space saving, simplify the wiring harness, reduce costs and facilitate the role of maintenance. Generally according to the need can be designed into 2 to 3. Some newly developed models of the distribution box has both electronic control functions; and no contact, no fuse central control box will be more and more market, with the Jet in the forefront. 3.2 wire color selection based on ZBT35002 "electronic and electrical use of low-voltage wire color" implementation. 3.3 selection of plugs a. According to the wire diameter and the size of the current through the selection of plugs; b. The engine compartment selected Sealed plug; c. Priority to the use of double spring-loaded compression structure of the plug to reduce the contact resistance. 3.4 Wiring harness wrapping a. Cabin is generally wrapped with tape at intervals; b. Instrument panel is generally used in the tape tightly wrapped; c. The floor or away from the engine parts, generally using flame-retardant corrugated pipe wrapping; e. Inside the door, inside the luggage compartment door is generally used to sticky tape or industrial plastic sheeting wrapping Forms; f. closer to the engine some of the region using wear heat-insulating glass wire casing or wire harnesses wrapped in glass ribbon. In addition to the above, attention should also be paid to: anti-theft ECU and read-write the distance between the coil, to prevent signal transmission attenuation; each signal transmission of electrical components such as "oxygen sensor", "shock sensor", "read-write coil The electrical parts such as "oxygen sensor", "burst sensor", "read/write coil", etc. should use LE-SE signal wire or shielded wire.

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