What are the wiring harness designs for the whole vehicle? How to design a complete vehicle wiring harness?

Whole vehicle wiring harness design refers to the process of wiring and connecting the overall electrical system of the car, which includes components such as connecting wires, cables and plugs between electrical devices, as well as connections to power supplies, sensors, control units and other related equipment. The following are the general steps in the design of the wiring harness for the entire vehicle: Determine the requirements and specifications: First of all, you need to understand the functional requirements and performance specifications of the entire vehicle, including the power requirements of the electrical system, the voltage level, the interface type, connector specifications and so on. This information will help determine the layout and composition of the harness. Wiring harness layout design: According to the layout of the whole vehicle and the location of electrical equipment, determine the path and layout of the wiring harness. Considering the safety, reliability and maintainability, the wiring harness should try to avoid contact with other mechanical parts or heat sources, and be easy to install and maintain. Electrical equipment connection: According to the function and connection requirements of the electrical system, determine the connection relationship between each electrical device. This includes the connection between the power supply, sensors, actuators, control units, etc. and the length of the wiring harness. Harness Length Calculation: Calculate the length of each harness based on the layout and connection requirements of the harness. This helps to determine the amount of material required and the cost of the harness, and ensures that the harness length is sufficient to avoid excessive length or shortness that could lead to installation difficulties or malfunctions. Wiring harness branching and identification: Based on the connection relationship, determine the branching points of the wiring harness and the location of the connectors. At the same time, in order to facilitate installation and maintenance, you can add identification for each connection point, such as number or color code. Selection of appropriate harness materials and specifications: According to power requirements, environmental conditions and safety requirements, select the appropriate harness materials and specifications. Common harness materials include polyvinyl chloride (PVC) and cross-linked polyolefin (XLPE). In addition, it is necessary to consider the characteristics of the harness such as abrasion resistance, water resistance and high temperature resistance. Wire Harness Securing and Protection: Ensure that the wire harness is not damaged by vibration, abrasion, or other environmental factors during the operation of the entire vehicle. Wire harnesses can be secured and protected with wire harness straps, sheaths, tubes, protective covers, etc. Electrical System Simulation and Verification: Simulation and verification of the electrical system is performed prior to actual manufacturing. Through the use of circuit simulation software, the design of the wire harness is verified to meet electrical requirements and performance specifications.

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