A Brief Analysis of the Wiring Harness Dilemma

Automotive wiring harness is the key component of the electrical system of automotive electronic products, and it is also the stage of frequent occurrence of common automotive faults. How to improve the reliability of automotive wiring harness work in the whole design process, reduce the failure rate of automotive equipment, and ensure fault detection in less time has become the focus of automotive electrical system design. The design of automotive electrical system begins with a new project of the whole vehicle or program. The important link of the key design steps is that the basic principle design of the electrical system and the three-dimensional layout of the electrical system must be carried out smoothly. If the basic principle design of electrical system is compared with life, then the three-dimensional layout of electrical system is the limbs carrying life. The quality of the three-dimensional layout of the electrical system immediately jeopardizes the quality of the development of the prototype. Efficient three-dimensional layout can reduce the problems in the whole research and development process, reduce the cost of research and development, and reduce the time of vehicle design. The key to the three-dimensional layout of the electrical system is to use CATIA, PRONE and other three-dimensional software to lay out the electrical components, electronic wiring harness and related fixed structures of the vehicle, including the three-dimensional layout of household appliances components and the three-dimensional layout of electrical equipment wiring harness, in which the key to household appliances components is to lay out according to the actual structure of the vehicle. Based on the experience of three-dimensional layout of automotive wiring harness, some basic principles and common problems are exchanged in this paper. The key is to discuss from the aspects of harness assembly, harness extensibility, harness security and reliability, which provides the basic design rules for the three-dimensional layout design of automotive electrical harness.

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General steps for 3D layout of automotive wiring harness. Automotive electrical system is divided into different control modules according to different components, such as automotive chassis, automotive dashboard, diesel engine, gearbox and so on. For each control module, the electrical equipment layout is carried out first, and the tasks are coordinated by the electrical system designer and the automotive technical engineer. After the electrical equipment layout scheme is defined, the harness alignment design shall be started. The harness alignment design shall be carried out according to the automotive electrical harness layout standard, and the alignment plan shall be calibrated until it is effective. After the wiring harness of electrical equipment is designed, the fixing method and structure shall be defined according to the wiring harness direction, the compressive strength and intervention calibration shall be carried out for the fixing method and structure, and the two-dimensional drawing of the wiring harness of electrical equipment shall be drawn according to the subsequent defined design scheme. Two-dimensional graph with respect to a fixed structure. The following is a key discussion of basic design criteria and frequently asked questions throughout the automotive wiring harness layout process. Basic standards and common problems of automotive wiring harness layout. When designing the three-dimensional direction of the car harness, we must fully integrate the food of the car body. The details of the attachment of wire harnesses such as window frames to the vehicle body, taking into account the comprehensiveness and comprehensiveness of the electrical equipment components of the vehicle. The harness arrangement design shall also consider the harness fixation and shall be based on the structure of food parts. The fixing method and the total number of supporting points of the vehicle mechanical system shall be specified; when there are many control panels and they need to be arranged in a centralized way, the arrangement of the control panels shall be mainly considered. The harness fixing structure is easy to assemble. When designing the harness fixing method and fixing structure, it is necessary to consider the assembly, not to improve too many processes in the pursuit of perfect fixing and reliable assembly, and to exchange the following common problems based on specific design experience. 1) Try to choose a simple fixing method, especially in areas with narrow indoor space, such as the wiring inside the door. White body and interior wiring, due to the narrow indoor space, try to choose plastic buckles or tape to fix. 2) The via-hole rubber sheath shall be designed to be fully assembled in the mikin hole with an installation force of less than 100 N. 3) The actual operating force is 45 N for the fixing card that must be riveted with fingers; the actual operating force for the fixing card of hand clamp is 75 N. 4) In the whole process of the design of the harness fixing structure and its related function box, try to select the commonly used standard parts, try to avoid the type of standard parts, and reduce the application of common tools in assembly and maintenance. 5) In view of the fact that the connector or harness fixing structure must pass through the vehicle cab during the assembly process, if the standard parts are general hexagon nuts and anchor bolts, it is difficult for one person to do it alone, so it is generally considered to select welding nuts or self-tapping screws for fixing. 6) The fixing hole of the harness shall be opened in the plan area of the part as far as possible. When the bevel is fixed, it is better to make a small plane on the part. 7) When laying out the harness of electrical equipment, the modular design and assembly of large total process shall be considered as far as possible to improve the assembly rate of production line. Uch as the transmission harness. The diesel engine wiring harness is assembled to the transmission and the diesel engine itself, respectively, and then to the vehicle chassis as a whole. 3. Summary With the development trend of automotive electronic and electrical technology, there are more and more automotive cutting machines, which put forward higher and higher regulations on the reliability of automotive electrical equipment wiring harness. In the design stage of electrical system, effective and reliable wiring harness layout of electrical equipment can reduce the development schedule, reduce the cost of automobile, and improve the reliability of electrical system work. How to use 3D software for more accurate 3D layout design of electrical equipment needs to be explored again.

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