How to design an automotive wiring harness? What are the things to look for in the design?

Automotive wiring harness is an important part of the automotive electronic system, which connects various electrical and electronic devices of the automobile so that the whole system can operate normally. Designing an efficient and reliable automotive wiring harness requires consideration of several factors, including electrical characteristics, mechanical characteristics, environmental characteristics and so on. The following will detail the design principles and considerations of automotive wiring harness. First, the electrical characteristics of 1.1. wire cross-sectional area selection: automotive wiring harness in the wire must be able to withstand the current load, and to ensure the normal transmission of current. Therefore, it is necessary to select the appropriate wire cross-section area according to the larger current in the harness and the length of the wire. Usually, the larger the wire cross-section area, the stronger the current transmission ability, but the cost will also be higher.1.2. Selection of insulating materials: the wires in automotive wiring harnesses need to use high-quality insulating materials to avoid safety problems such as electrical failures and fires. Currently, the commonly used insulating materials on the market are PVC, PE, PP, Teflon, etc. The design should be based on different needs to choose the appropriate insulating material.1.3. Consideration of electromagnetic compatibility: electromagnetic interference will be generated between various parts in the automotive wiring harness, so electromagnetic compatibility needs to be considered in the design. This includes the selection of appropriate cable layout, protective measures and shielding materials. Second, the mechanical characteristics 2.1. bending radius considerations: in the design of automotive wiring harnesses, the wire bending radius needs to be considered to ensure that the wiring harness can adapt to a variety of curves and angles of the car. Usually, the minimum bending radius of the wire should be within 3 to 5 times the diameter of the wire to avoid wire breakage and wear.2.2. Requirements for tensile strength: Automotive wiring harnesses will be subjected to tensile force in different directions in the process of use, and therefore the tensile strength of the harness needs to be considered. This includes the use of high-strength materials and the design of appropriate connectors and support structures, etc. 2.3. waterproof performance considerations: automotive wiring harnesses usually need to have waterproof performance to ensure that the wiring harness can work properly in a wet environment. It is necessary to choose suitable waterproof materials and adopt waterproof connectors in the design to prevent water intrusion into the wiring harness and cause failures.

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