The production process of automotive wiring harnesses is revealed.

The production process of automotive wiring harness big secret, the following automotive wiring harness processing plant for everyone: wiring harness process in the wiring harness two-dimensional product drawings come out, to program the wiring harness production process, automotive wiring harness process is inextricably linked to the production of the two, and therefore the two will be combined together to analyze. Open wire process is a wire harness production of a station, the accuracy of the open wire process is directly related to the entire production schedule, once the error is particularly short open wire size, will lead to rework of all stations, time-consuming and labor-intensive impact on production efficiency. So in the preparation of the open wire process must be based on the requirements of the drawings to reasonably determine the size of the wire open wire, stripping head size. Production of open wire operating instructions, production process tracking card. Crimping process after the opening of the second production station, according to the drawing requirements of the terminal type to determine the crimping parameters, the production of crimping instructions, for special requirements need to be specified in the process documentation and training of operators. For example: some wires need to pass through the sheath before crimping, it is necessary to first pre-installed wire and then return from the pre-installation station and then crimp; there are also piercing crimping with a special crimping tool, this crimping method has good electrical contact properties. Pre-assembly process to prepare a pre-assembly process operating instructions, in order to improve the total assembly efficiency, complex wiring harnesses should be set up to pre-assembly station, pre-assembly process is reasonable or not directly affects the total assembly efficiency also reflects the technical level of a craftsman high and low. If the pre-installed part of the assembly is less or the assembly of the wire path is not reasonable will increase the workload of the total assembly personnel, slowing down the speed of the assembly line, so the process staff should always stay in the field and constantly summarize the experience, so that we can prepare a reasonable production process. General assembly process according to the product development department designed assembly board, design equipment, material box specifications and size and will be all assembled sheaths and accessories of the number affixed to the material box in order to improve the assembly efficiency. Preparation of each station assembly content and requirements, balancing the entire assembly station to prevent a point of excessive workload, pulling down the speed of the entire assembly line. To achieve workplace balance, process personnel must be familiar with each operation and on-site measurement of working hours, adjust the assembly process at any time. Wiring harness process also includes the preparation of material consumption quota schedule, time measurement, worker training and so on. Automotive wiring harnesses mainly to the terminal wire-based, welding, molding are not too much, so the main investment is the terminal machine, and usually semi-automatic terminal machine can be completely satisfied to fully automatic terminal machine is too much of a waste of money, there is a molding machine (about 20,000 a), testing machines, tensile strength machine, stripping machine, wire cutting machine, soldering machine, electronic weighing machine, punching machine

Automotive wiring harness production process and production process 1) wire cutting will require a variety of wire cutting to the required length 2) terminal crimping will be crimped to the terminal wire 3) sub assembly sub assembly installation of connectors and other small strands of wires 4) assembly assembly will be a variety of small strands of wires in the assembly of a large assembly board, wrapped with tape, installation of various protective components (bellows, protective brackets, etc.) 5) testing in a special test board to detect whether the circuit is smooth, appearance testing, grommet waterproof testing and other wiring harness production process is to open the wire - crimping - pre-assembly - pre-wiring harness is open - crimping - appearance testing, grommet waterproof testing and other production processes. ) testing in the specialized testing board to detect whether the circuit is smooth, appearance testing, grommet waterproof testing and other wiring harness production process is open line - crimping - pre-installation - general assembly - testing - the -General assembly - Inspection - Electrical testing - Packaging - Shipping in the At present, whether it is a luxury car or an economical ordinary car, the wiring harness braided form is basically the same, are composed of wires, joint inserts and wrapping tape. Automobile wires, also known as low-voltage wires, are different from ordinary household wires. Ordinary household wires are copper single-piston wires, with a certain degree of hardness. And automotive wires are copper multi-piston wire, some soft wire as thin as a hair, several or even dozens of soft copper wire wrapped in plastic insulation tube (PVC), soft and not easy to break. Due to the specificity of the automotive industry, the manufacturing process of automotive wiring harnesses is also more special than other common wiring harness. Manufacturing automotive wiring harness system is divided into two categories: 1. Europe and the United States, including China: the use of TS16949 system to control the manufacturing process. 2. 2. Japan-based: such as Toyota, Honda, they have their own system to control the manufacturing process. With the increase of automobile functions, the common application of electronic control technology, more and more electrical parts, wires will be more and more, the wiring harness will become thicker and heavier. This is why advanced automobiles have introduced CAN bus configurations that utilize a multiplexed transmission system. Comparing with the traditional wiring harness, the multiplex transmission device greatly reduces the number of wires and connecting plug-ins, making the wiring easier.

Edit this section of the common specifications of the wires in the automotive wiring harness commonly used specifications have a nominal cross-sectional area of 0.5, 0.75, 1.0, 1.5, 2.0, 2.5, 4.0, 6.0 and other square millimeters of wire (Japanese cars commonly used nominal cross-sectional area of 0.5, 0.85, 1.25, 2.0, 2.5, 4.0, 6.0 and so on square millimeters), which are each permissible value of the load current, and the wires used for different power equipment. The wires are used for different power devices. Taking the wiring harness of the whole car as an example, 0.5 specification wire is suitable for instrument lamps, indicator lamps, door lamps, roof lamps, etc.; 0.75 specification wire is suitable for license plate lamps, front and rear lamps, brake lamps, etc.; 1.0 specification wire is suitable for turn signal lamps, fog lamps, etc.; 1.5 specification wire is suitable for headlamps, horns, etc.; the main power wires, such as the generator armature wires and the hitch wires, etc., require 2.5-4 square millimeters of wires. This only refers to the general car, the key to look at the load of the greater current value, such as battery hitch wire, positive power line is a special car wire alone, their wire diameter are relatively large, at least more than a dozen square millimeters, these "giant" wires will not be programmed into the main wiring harness. Edit this section of the wiring harness arrangement in the arrangement of the wiring harness beforehand to draw a wiring harness diagram, wiring harness diagram and circuit schematic is not the same. The schematic circuit diagram is an image of the relationship between the electrical parts, it does not reflect how the electrical parts are connected to each other, and is not affected by the size and shape of the electrical components and the distance between them. A wiring harness diagram, on the other hand, must take into account the size and shape of the electrical components and the distance between them, and must also reflect how the electrical parts are connected to each other. Wiring harness factory technicians according to the wiring harness diagram made of wiring harness wiring board, the workers in accordance with the provisions of the wiring board to cut the line line line. The main wiring harness of the whole car is generally divided into the engine (ignition, EFI, power generation, starting), instrumentation, lighting, air conditioning, auxiliary appliances and other parts of the main wiring harness and branch wiring harness. An entire vehicle main harness has multiple branch harnesses, just like a tree pole and branches. The main wiring harness of the whole vehicle often takes the instrument panel as the core part and extends front and back. Due to the length of the relationship or ease of assembly and other reasons, the wiring harness of some cars is divided into the front wiring harness (including instrumentation, engine, front light assembly, air conditioning, battery), the rear wiring harness (taillight assembly, license plate light, luggage compartment light), the roof wiring harness (doors, roof lights, audio speakers) and so on. Wiring harness on each end will be marked numbers and letters to indicate the connection object of the wire, the operator sees the sign can be properly connected to the corresponding wires and electrical devices, which is particularly useful in the repair or replacement of the wiring harness. At the same time, the color of the wire is divided into single-color wire and two-color wire, the use of the color is also stipulated, usually the car factory self-defined standards. Our industry standards only specify the main color, for example, the provisions of the single black dedicated to the hitch wire, red monochrome for the power cord, not to be confused. Wiring harness with woven wire or plastic sticky tape package, for safety, processing and maintenance convenience, woven wire package has been eliminated, is now wrapped in sticky plastic tape. The connection between the wire harness and the wire harness, between the wire harness and the electrical parts, using the joint plug-in or wire lugs. Plugs made of plastic, divided into plugs and sockets. The wiring harness is connected to the wiring harness with a plug-in, and the connection between the wiring harness and electrical parts is made with a plug-in or lugs. This section of the harness material automotive wiring harness on the material requirements are also very strict: including its electrical properties, material dispersion, temperature resistance, etc., are higher than the general requirements of the wiring harness, especially when it comes to safety: such as the direction of the control system, brakes, these important components of the wiring harness, the requirements of a more stringent.

This paragraph of the automotive wiring harness function in modern automobiles, automotive wiring harnesses in particular, electronic control systems and wiring harnesses have a close relationship. Someone once played a figurative analogy: if the microcomputer, sensors and the function of the executive element with the human body to the analogy, it can be said that the microcomputer is equivalent to the human brain, the sensor is equivalent to the sensory organs, the executive element is equivalent to the movement of the tube, then the wiring harness is the nerves and blood vessels. Automotive wiring harness is the main body of the network of automotive circuits, connecting the electrical and electronic components of the car and make it function, there is no wiring harness there is no automotive circuit. At present, whether it is a luxury car or economic ordinary car, the wiring harness is basically the same form, are composed of wires, plug-ins and wrapping tape, it should ensure that the transmission of electrical signals, but also to ensure the reliability of the connection circuit to the supply of electronic and electrical components to the current value of the provisions of the circuit to prevent electromagnetic interference with the surrounding circuits, and to exclude electrical short-circuit. Automotive wiring harness from the function, there are two kinds of power lines and signal lines that carry the power to drive the executive element (actuator) and transmit the sensor input instructions. Power line is a thick wire to transport large currents, while the signal line is not carrying power of fine wires (fiber optic communication); for example, the signal circuit with a wire cross-sectional area of 0.3, 0.5mm2. In the motor, the implementation of the component with a wire cross-sectional area of 0.85, 1.25mm2, while the power supply circuit with a wire cross-sectional area of 2, 3, 5mm2; and special circuits (starter, alternator, engine) is a special circuit (starter, alternator, engine). The special circuit (starter, alternator, engine grounding wire, etc.) are 8, 10, 15, 20mm2 different specifications. The larger the cross-sectional area of the wire, the larger the current capacity. Wire selection, in addition to considering the electrical properties, but also by the vehicle when the physical properties of the constraints, so its choice of a wide range. For example, the wires between the frequently opened/closed doors and across the body of a rental car should consist of wires with good flexural properties. For wires used in high-temperature areas, vinyl chloride and polyethylene-coated wires with good insulation and heat resistance are generally used. In recent years, the use of electromagnetically shielded wires for weak signal circuits has also increased. With the increase in automobile functions, the universal application of electronic control technology, more and more electrical parts, wires will be more and more, the number of circuits in the car with a significant increase in electricity consumption, the wiring harness also becomes thicker and heavier. This is a big problem that needs to be solved, how to make a large number of harnesses in the limited space of the car how to be more effective and reasonable arrangement, so that the automotive wiring harness to play a greater function, has become a problem faced by the automotive manufacturing industry. This paragraph of the automotive wiring harness process and production with people's comfort, economy, safety requirements continue to improve, the types of electronic products on the car is also increasing, the automotive wiring harness is becoming more and more complex wiring harness failure rate also increased accordingly. This requires improving the reliability and durability of the harness and other properties, many people are more interested in the process and production of automotive wiring harnesses, here Huicheng yuan electronics on the automotive wiring harness process and production of this knowledge to do a simple narrative, you only need to spend a few minutes to read, you can generally understand. In the automotive harness two-dimensional product drawings out, to program the production process of the harness, the process is to serve the production of the two are inseparable, so the author will be the production of automotive wiring harnesses and the process of combining the two together to analyze. Harness production of a workstation is to open the line process. The accuracy of the open wire process is directly related to the entire production schedule, once the error is particularly short of the open wire size, will lead to rework of all stations, time-consuming and labor-intensive impact on production efficiency. So in the preparation of the open wire process must be based on the requirements of the drawings to reasonably determine the size of the wire open wire, stripping head size. After the opening of the second station is the crimping process, according to the drawing requirements of the terminal type to determine the crimping parameters, the production of crimping instructions, for special requirements need to be specified in the process documentation and training of operators. For example: some wires need to pass through the sheath before crimping, it needs to be pre-installed wire and then return from the pre-installation station and then crimp; there are also puncture crimping with a special crimping tool, this crimping method has good electrical contact properties. Then there is the pre-installation process, first of all, to prepare the pre-installation process operating instructions, in order to improve the efficiency of the total assembly, the complexity of the wiring harness should be set up to pre-installation stations, pre-installation process is reasonable or not directly affects the efficiency of the total assembly also reflects the technical level of a craftsperson high and low. If the pre-assembly part of the assembly of the lesser or assembly of the wire path is unreasonable will increase the workload of the total assembly personnel, slowing down the speed of the assembly line, so craftsmen should often stay in the field and constantly summarize. The last step is, the total assembly process. Able to compile according to the product development department designed assembly board, design equipment, material box specifications and size and will be all assembled sheaths and accessories of the number affixed to the material box in order to improve the assembly efficiency. Preparation of each station assembly content and requirements, balancing the entire assembly station to prevent a point of excessive workload, pulling down the speed of the entire assembly line. To achieve workplace balance, process personnel must be familiar with each operation and on-site measurement of man-hours, at any time to adjust the assembly process. In addition, the harness process also includes the preparation of material consumption quota schedule, time measurement, worker training, etc., due to the value of the technical content is not high, these are not detailed. In short, the automotive wiring harness in the car electronic technology content and quality, and gradually become an important indicator of the evaluation of automotive performance. Automobile manufacturers should pay particular attention to the choice of wiring harness, it is also necessary to understand the process and production of automotive wiring harness. Today's automotive wiring harness production process automotive wiring harnesses are becoming more and more complex wiring harness failure rate has increased accordingly that is due to people's comfort, economy, safety requirements continue to improve, the types of electronic products on the car is also increasing. This requires improving the reliability and durability of the harness and other properties, many people are more interested in the process and production of automotive wiring harnesses, here Huicheng yuan electronics on the automotive wiring harness process and production of this knowledge to do a simple narrative, you only need to spend a few minutes to read, you can generally understand. In the automotive harness two-dimensional product drawings out, to program the production process of the harness, the process is to serve the production of the two are inseparable, so the author will be the production of automotive harnesses and the process of combining the two together to analyze. Automotive wiring harness production process: automotive wiring harness production of a station is the open wire process. The accuracy of the open wire process is directly related to the entire production schedule, once the error is particularly short of the open wire size, will lead to rework of all stations, time-consuming and labor-intensive impact on production efficiency. So in the preparation of the open wire process must be based on the requirements of the drawings to reasonably determine the size of the wire open wire, stripping size. Automotive wiring harness after the opening of the second station is crimping process, according to the drawing requirements of the terminal type to determine the crimping parameters, the production of crimping instructions, for special requirements need to be specified in the process documentation and training of operators. For example: some wires need to pass through the sheath before crimping, it needs to be pre-installed wire and then return from the pre-installation station and then crimp; there are also punctured crimp with a special crimping tool, this crimping method has good electrical contact properties. Automotive wiring harness is then pre-assembly process, the first to prepare the pre-assembly process operating instructions, in order to improve the total assembly efficiency, complex wiring harnesses should be set up to pre-assembly station, pre-assembly process is reasonable or not directly affects the efficiency of the total assembly also reflects the technical level of a craftsman. If the pre-assembly part of the assembly is less or assembly of the wire path is not reasonable will increase the total assembly staff workload, slowing down the speed of the assembly line, so the process staff should always stay on site to constantly summarize. The last step of the automotive wiring harness is the final assembly process. Able to compile according to the product development department designed assembly board, design equipment, material box specifications and size and will be all assembled sheaths and accessories of the number affixed to the material box in order to improve the assembly efficiency. Preparation of each station assembly content and requirements, balancing the entire assembly station to prevent a point of excessive workload, pulling down the speed of the entire assembly line. To achieve workplace balance, process personnel must be familiar with each operation and on-site measurement of working hours, adjust the assembly process at any time. In addition, the automotive wiring harness process also includes the preparation of material consumption quota schedule, time measurement, worker training, etc., due to the technical content of the value is not high, these are not detailed. In short, the automotive wiring harness in the car electronic technology content and quality, and gradually become an important indicator of the evaluation of automotive performance. Automobile manufacturers should pay particular attention to the choice of harness, it is also necessary to understand the process and production of automotive wiring harness. Automotive wiring harness design and wiring harness with raw materials automotive wiring harness is the main body of the network of automotive circuits, there is no wiring harness there is no automotive circuits. As people's safety, comfort, economy and emission requirements of automobiles improve, automotive wiring harnesses have become more and more complex, but the body gives less and less space for wiring harnesses. Therefore, how to improve the comprehensive performance of automotive wiring harness design has become the focus of attention, and automotive wiring harness manufacturers are no longer simply engage in the wiring harness late design and manufacturing, and automotive manufacturers to jointly carry out the pre-development of the inevitable trend. According to a few years engaged in harness design and manufacturing experience, talk about the general design process and design principles of the harness. First, the car circuit design (a) power distribution design of the car's power supply system design is reasonable, directly related to the normal operation of the car electrical parts and the safety of the car, so the world's automotive wiring harness design starting point is basically safety-oriented. The electrical system of the whole car is basically composed of 3 parts. Battery direct power supply system (generally known as normal power or 30 power). This part of the power supply is generally connected to the load of the car's safety or important parts, the main purpose is to provide electrical energy for these parts as little as possible to control, to ensure that these parts of the car even if the car does not start up can also be a short period of time to work normally, in order to facilitate to the site maintenance, and so on. Such as: engine ECU and engine sensor power supply, fuel pump power supply, ABS controller power supply, diagnostic interface power supply. Ignition switch control of the power supply system (generally known as the IG file or coincidental power). This part of the electrical parts are basically used only when the engine is working and running, taken from the generator's power supply, avoiding the possibility of contending for power when charging the battery. For example: instrument power supply, brake light power supply, airbag power supply and so on. The power supply that unloads the load when the engine starts (generally known as the ACC power supply). This part of the electrical components generally carry a larger load, and do not have to work when the car starts. Generally, there are cigarette lighter power supply, air conditioning power supply, radio power supply, wiper power supply and so on. (B) line protection design line protection is to protect the wire, taking into account the protection of the circuit electrical components. Protective devices are mainly fuses, circuit breakers and fusible wire. 1. fuse selection principle engine ECU, ABS and other vehicle performance and safety impact, in addition, vulnerable to other electrical equipment, electrical parts must be a single fuse. Engine sensors, various types of alarm signal lamps and external lighting, speakers and other electrical parts of the vehicle performance and safety is also a greater impact, but this type of electrical load is not sensitive to the interference between each other. Therefore, such electrical loads can be combined with each other according to the situation and use a fuse together. For the increase of comfort and set the general electrical parts of the electrical load can be based on the circumstances of the combination of each other, the common use of a fuse. There are fast-fusing and slow-fusing types of fuses. The main part of the fast-fusing fuse is a fine tin wire, which is widely used because of its simple structure, good reliability and vibration resistance, and ease of detection; the slow-fusing fuse is actually a tin alloy piece, and the fuse of this structure is generally connected in series to the circuit of inductive loads, such as motor circuits. Resistive loads and inductive loads try to avoid using the same fuse. Generally based on the electrical components of the greater continuous operating current to calculate and determine the fuse capacity, can be based on the empirical formula: fuse rated capacity = circuit greater operating current ÷ 80% (or 70%). 2. Circuit Breakers Circuit breakers are more characterized by the restorability, but its cost is higher, less use. Circuit breakers are generally thermo-mechanical devices, which utilize the different thermal deformations of two metals to open and close contacts or turn themselves on. Newer circuit breakers, use PTC solid material as an overcurrent protection element, which is a positive temperature coefficient resistor that breaks or turns on depending on the current or temperature. The greater advantage of this protection element is that when the fault is removed can be automatically connected, do not need to manually adjust and dismantle. 3. fusible wire fusible wire is characterized by when the line through the great overload current, fusible wire can be in a certain period of time (generally ≤ 5s) fused to cut off the power supply to prevent the occurrence of malicious accidents. Fusible wire is also composed of conductor and insulation layer, insulation layer is generally chlorosulfonated polyethylene material, because the insulation layer is thicker, so look. Thicker than the same size wire. Fusible links are generally connected to the battery directly out of the circuit. Fusible wire commonly used nominal cross-section of 0.3mm2, 0.5mm2, 0.75mm2, 1.0mm2, 1.5mm2, and even 8mm2 and other larger cross-section of fusible wire. Fusible wire segment length is divided into (50 ± 5) mm, (100 ± 10) mm, (150 ± 15) mm 3 kinds. Fusible wire should have a clear sign, when it fuses, the sign should still exist in order to facilitate the replacement. Fusible wire fusing characteristics shown in Table 1. (C) the selection of relay design relays are divided into current and voltage type 2 kinds. Generally according to the power of the electrical appliances and the carrying capacity of the switch to decide whether to choose the relay. Commonly used relays are generally wiper, horn, defrost, headlights, fog lights, fans, blowers, turn signals (flasher) and other equipment. Relay 6V, 12V, 24V 3 kinds, commonly used relay rated voltage of 12 V. Selection of relay to refer to the technical requirements: ① good reliability; ② stable performance; ③ light weight, small size, long life, small impact on the surrounding components; ④ simple structure, good workmanship, low cost. (D) lap distribution design principles engine ECU, ABS, etc. on the vehicle performance and safety impact, and susceptible to other electrical equipment interference, so these parts of the lap point must be set up separately. For the airbag system, its iron point should not only be single, and in order to ensure its safety and reliability, better use of compound iron. The purpose is that one of the hitch failure, the system can be through another hitch point hitch, to ensure that the system works safely. Radio system in order to avoid interference, but also a separate iron. Weak signal sensor lap iron is better independent, lap iron point is better in the position closer to the sensor to ensure the true transmission of the signal. Other electrical parts can be combined with each other according to the specific layout of the common iron point. The principle is close to the lap iron, to avoid the lap iron line is too long, resulting in unnecessary voltage drop. Negative battery line, engine hitch line and so on because the wire cross-section is large, so be sure to control the line length and direction, reduce the voltage drop; in order to increase safety, the engine, the body is generally connected to the battery negative iron alone; hitch way: one is through the hole type connector hitch, this method must be baked on the end of the connector heat-shrinkable tube insulation; the second is through the internal shorting of sheaths directly on the iron. Second, the wiring harness three-dimensional layout towards the design of this process is mainly simulated simulation of different areas of the wiring harness towards the diameter, considering the wiring harness over the hole sealing and protection, simulation of the wiring harness of the fixed holes and fixing methods, such as shown in Figure 1. Three-dimensional wiring with the main software PRO-E, UG and CATIA and so on. Third, the selection of plug design plug is the core component of the wiring harness, plug performance directly determines the overall performance of the wiring harness, but also on the vehicle's electrical stability, safety plays a decisive role. (A) the selection of plug design principles plug selection to ensure good contact with electrical parts, so that the contact resistance to lower, improve reliability, give priority to the selection of double spring-type compression structure of the plug. According to the cross-sectional area of the wire and the size of the current through the reasonable choice of plug. Engine compartment docking jacket, due to the cabin temperature, humidity and the presence of a lot of corrosive gases and liquids, so be sure to choose a waterproof jacket. If you use the same kind of sheath in the same wiring harness, the color must be different. Based on the overall coordination of the appearance of the car, in the engine compartment should give priority to the use of black or dark color of the sheath. In order to reduce the type and number of sheaths for wiring harness butt joints, give priority to the use of hybrid parts, so that the assembly is easy to fix. For the higher performance requirements of airbags, ABS, ECU and other terminal plugs, should give priority to gold-plated parts to ensure safety and reliability. Battery connector (battery clamps) internal cone, taper 1:9; battery clamps material for tinned copper, galvanized copper or lead-antimony alloy. Different specifications of the plug can carry the current is generally as follows: 1 series, about 10A; 2.2 or 3 series, about 20A; 4.8 series, about 30A; 6.3 series, about 45A; 7.8 or 9.5 series, about 60A. (B) plug-in raw materials (materials) performance analysis 1. sheath material (plastic parts) commonly used materials are PA6, PA66, ABS, PBT, pp, etc., the author summarizes their specific performance differences, see Table 2. design plug-ins can be selected according to the different needs of different materials, but also according to the actual situation of the plastic in the addition of flame-retardant or reinforcing materials, in order to achieve the purpose of enhancement or flame-retardant 2. terminal material (copper parts) plug with copper is mainly brass and bronze (brass hardness is slightly lower than the hardness of bronze), of which brass accounted for a larger proportion. In addition, different plating can be selected according to different needs. Fourth, the wire selection design (a) the choice of wire type wire harness design selection of wire type focus on the environment and function of the wire harness. For example, the environment around the engine is high temperature, corrosive gases and liquids are also many. Therefore, we must use high temperature, oil, vibration and friction resistant wire; luggage compartment cover wire to maintain its elasticity at low temperatures, so we must choose the cold elastic wire to ensure its normal operation; automatic transmission wire must be resistant to high temperatures, resistant to hydraulic oil, and its temperature stability should be good; weak signal sensors should be used with a shielded wire, such as vibration sensors and crankshaft position sensors, ABS wheel speed sensors, etc.; door wire bending resistance requirements. The wire inside the door requires high bending resistance. Automotive wiring harnesses commonly used wires usually use multi-stranded stranded copper wires, the insulation skin for the PVC insulation material. The wiring harness wire should have temperature resistance, oil resistance, abrasion resistance, water resistance, corrosion resistance, oxidation resistance, flame retardant and other characteristics. Automotive wiring harnesses commonly used wire types are Japanese standard (AVSS, etc.), national standard (QVR), German standard (FLRY), American standard and other major series. AVSS (AVS) wire is characterized by a thin skin insulation, better flexibility; QVR is characterized by a thick insulating skin, softer, better ductility; German standard wire insulating skin is thinner, better flexibility; American standard wire insulating skin is generally thermoplastic or thermosetting elastomers, and after the irradiation process. The wire insulation skin is generally thermoplastic or thermosetting elastomer, and there are also processed by irradiation process. According to the user's needs and different working environments to select the appropriate type of wire. (B) calculate the selection of the cross-section area of the wire according to the size of the power of the electrical components to calculate the current flow of the wire; long working hours of electrical equipment can choose the actual current-carrying capacity of 60% of the wire; short working hours of electrical equipment can be used to choose the actual current-carrying capacity of 60% - between the wire. According to different working environments and temperature size of the appropriate change in the cross-sectional area of the wire. According to the direction of the wire, the number of plugs (i.e., the size of the voltage drop) to change the cross-sectional area of the wire. On the calculation of the cross-sectional area of the wire, there are also some experts summarized some empirical formulas: I = P / UsA = IρL / Ud where: I - current; P - power; Us - system voltage; A - the conductor. - system voltage; A - conductor cross-sectional area; Ud - allow greater voltage drop loss; ρ - copper resistivity; L - conductor length. Or according to the following empirical formula: I = A × 10 + 8 / 2 allowable current flow and conductor cross-sectional area of the relationship between the empirical theoretical value (larger than the calculated value according to the above formula) shown in Table 3. Fifth, the whole car harness seals (rubber parts) design of the automotive wiring harness over the hole when the general use of rubber parts for the transition, in order to play a wear-resistant, waterproof, sealing and other roles. Mainly distributed in the following parts: engine and cab interface, front cabin and cab interface (left and right a total of 2 places), four doors (or back door) and compartment interface, fuel tank inlet. Commonly used materials are generally natural rubber, neoprene, silicone rubber, EPDM and so on. Characteristics of natural rubber: good elasticity and mechanical strength, excellent flex resistance, high tear strength and good cold resistance. Disadvantages: aging resistance is not very good, not resistant to oil and ozone, flammable. Properties of neoprene rubber: ozone resistance, heat aging resistance, oil resistance and other properties, flame retardant and self-extinguishing; but low temperature resistance is not good. Properties of silicone rubber: better heat resistance, cold resistance and weather resistance; the disadvantage is not oil resistance. EPDM characteristics: marina resistance, ozone resistance, heat resistance, corrosion resistance, acid and alkali resistance and other properties are better, and has a high strength and high expansion rate; disadvantages: poor adhesion, and the elasticity is not as good as natural rubber, poor oil resistance. Comparatively speaking, EPDM has better overall performance, so now the automotive wiring harness with rubber parts generally choose EPDM materials. Six, the whole car harness wrapping and fixed design (a) harness wrapping design harness outside the wrapping to play a wear-resistant, flame-retardant, corrosion-resistant, prevent interference, reduce noise, beautify the appearance of the role of the general working environment and the size of the space to develop the following wrapping design program. The engine wiring harness has a harsh working environment, so it is wrapped with high flame retardant, waterproof and high mechanical strength bellows. The working environment of the front cabin line is also relatively poor, most of the branches are also wrapped with good flame retardant bellows, and some of the branches are wrapped with PVC pipes. Instrumentation line working space is smaller, the environment is relatively good, available tape all wrapped or flower wrapped. Door line and roof line work space is small, can be fully wrapped with tape, part of the branches can be wrapped with industrial plastic cloth; finer roof line can be directly sponge tape on the car body. Chassis line because of more contact parts with the car body, so use bellows wrapping to prevent wear and tear of the wiring harness. (B) the performance analysis of raw materials used for wrapping 1. bellows bellows in the harness wrapping generally accounted for about 60%, or even more. The main feature is better abrasion resistance, high temperature resistance in the high temperature zone, flame retardant, heat resistance are very good. The temperature resistance of bellows is between -40-150℃. Its material is generally divided into PP and PA 2 kinds, PA material in flame retardant, wear-resistant than PP material; but PP material in the bending fatigue resistance is stronger than the PA material. 2.2.2.2 PVC pipe PVC pipe PVC pipe function and corrugated pipe is almost the same, PVC pipe softness and bending deformation resistance is better, and the PVC pipe is generally closed, so PVC pipe is mainly used in the wiring harness corner of the branch, in order to make wire smooth transitions. PVC pipe's heat-resistant temperature is not high, generally below 80 ° C. 3. Tape tape in the harness to play a role in the bundling, wear-resistant, insulating, flame retardant, noise reduction, marking and so on, in the wrapping materials generally accounted for about 30%. Harness tape is generally divided into PVC tape, air flannel tape and cloth-based tape 3 kinds of PVC tape wear resistance, flame retardant better; temperature in 80 ℃ or so, noise reduction is not good, the price is cheaper. The material of flannel tape and cloth tape is PET, the wrapping and noise reduction of flannel tape is better, the temperature resistance is about 105℃; the abrasion resistance of cloth tape is better, the temperature resistance is higher about 150℃. The common disadvantage of flannel tape and cloth-based tape is that they are not flame retardant and expensive.6.3 Wiring harness fixing designThe central electrical box is generally fixed with steel slats, bolts, etc., or directly mounted on the body of the car with the fixing structure designed by the electrical box itself. Each wiring harness is generally fixed in the body holes with plastic ties, snap hooks and so on. Most of the body holes are round or oval holes, generally 5mm, 6mm, 7mm in diameter. The sheaths for the butt joints between the various harnesses are generally fixed up collectively with sheath brackets and mounted on the body. Sea Lion, MPV and other larger models of the body line is long and thick, generally fixed in the body with a shield to reduce vibration and noise. Information Source: Automotive Electrical Wiring Harness Connectors Wiring harness connectors are a type of terminal, connectors, also known as plugs, consist of plugs and sockets. The connector is a relay station for the wiring harness in the automobile circuit. The connection between the wiring harness and the wiring harness, the wiring harness and the electrical components generally use connectors, automotive wiring harness connector is an important part of the connection between the various electrical and electronic equipment in the car In order to prevent the connector from disengaging in the automobile driving, all connectors use a latching device. Wiring harness connector connection method Wiring harness connector is a kind of terminal, the connector is also known as plug, by the plug and socket composition. The connector is a relay station for the wiring harness in the automobile circuit. The connection between the wiring harness and the wiring harness, the wiring harness and the electrical components are generally used connectors, automotive wiring harness connectors are important parts of the car to connect the various electrical and electronic equipment In order to prevent the connector from disconnecting in the automobile driving, all the connectors are using a latching device. Wiring harness connector disassembly method to disassemble the connector, first of all, to release the latch, and then pull the plug apart, do not allow in the case of unlocking the situation of pulling the wiring harness with force, which will damage the latch device or connecting wiring harness. Wiring harness connector features such as automotive wiring harness connector is an important part of connecting various electrical and electronic equipment in the car, in the power supply, switches, electrical appliances and electronic equipment between the transmission of electrical signals, known as the automotive nerve of the car is the carrier of the electrical signal control of the car. It is characterized by good air tightness and beautiful appearance. Main Features 1.Unipolar 75 amp connectors and terminals 2.Operating voltage: 600 volts, (AC or DC are available) 3.Plugging life: more than 5000 times 4.Withstand insulation voltage: 2200 volts 5.On-resistance: 100 micro ohms. Application of wire harness connector products wire harness connector products used in automotive, home appliances, instrumentation, office equipment, commercial machinery, electronic parts lead. Electronic control boards, used in digital products, household appliances, automotive industry. With the increase of automobile functions, the universal application of electronic control technology, more and more electrical parts, wires will be more and more! Harness connector market outlook in recent years, China's rapid growth in the production of cell phones has led to a large demand for cell phone connectors. Cell phone connectors, to battery connectors, SIM card connectors, FPC connectors demand is greater, accounting for about 50 [%] of the total demand. According to Global Sources market research report, in 2004, driven by outstanding demand in the computer and consumer electronics market, China's mainland connector market will show double-digit growth. Many local connector manufacturers started out as mold developers or manufacturers and then gradually penetrated into connector manufacturing. Because of their mold development, manufacturing and plastic molding capabilities, they have a considerable competitive advantage, both in terms of cost control and rapid response to customers and the market in comparison. Harness connector development history of connector products began during World War II, mainly used in the military industrial enterprises, with the end of World War 2, on the supply of connectors and harnesses, the current market is in a situation where supply exceeds demand. China's general-purpose connectors and harnesses in the automotive field of application and development, has a history of more than 50 years.

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