Types and Compositions of Automotive Wire Harnesses

The service object of the wire harness is the load source. It refers to the wire harness assembled with wires and connecting terminals and other parts. It is a carrier for transmitting power and accelerating the transmission of signals, and a communication link in various fields of automobiles.

Automotive wire harnesses can be divided into full-utilization wire harnesses, partial-utilization wire harnesses and link systems according to different structures; they can be divided into loss-controlled wire harnesses and waiting-controlled wire harnesses according to different service modes; they can be divided into unlimited load wire harnesses and limited load source wire harnesses according to the number of attached sources served. In addition to these, there is another classification, which is to divide it into main wire harnesses and small wire harnesses. This statement is distinguished according to the number of parts. Among them, the main wire harness includes engine wire harnesses, floor wire harnesses, instrument panel wire harnesses, etc., and the small wire harnesses include ceiling wire harnesses, reversing radar wire harnesses, door wire harnesses, etc.

The so-called wire harness is to bundle multiple wires into bundles with insulating materials, and combine wires of different colors and specifications into one, which is more complete and unified, and convenient for its safety. 60% of the actual current carrying capacity of the wire and 60% to 100% of the actual current carrying capacity of the wire are suitable for two types of electrical equipment that work for a long time and for a short time, respectively. The cross-sectional area of the selected wire is selected according to the load current size of the automotive electrical equipment. In order to facilitate the recognition of the wires in each wiring harness, different colors and letters representing the color are used. The wiring harness is generally assembled by plastic parts, terminals, wires, line protectors, rubber parts, brackets, fixings and other attachments (including tapes, sleeves) according to certain process steps. If the Plato is made according to the proportion of the raw material cost of the wiring harness, then the cost of the three types of materials, wires, plastic parts, and terminals, accounts for the largest proportion. The raw materials of the wiring harness are mainly purchased parts. The main way to control the cost of raw materials is to optimize the raw material costs of the three parts of wires, plastic parts, and terminals through benchmarking and VAVE methods.

The wire requirements in various parts of the automotive wiring harness are strict and unique. Most of them are from the aspects of its electrical performance, temperature resistance and material dissipation. For example, the wires of the engine harness must be high temperature, oil resistant, vibration resistant and friction resistant; the wires on the automatic transmission are high temperature resistant, hydraulic oil resistant and stable; the harness on the trunk lid must be selected to maintain its inherent elasticity in a low temperature environment, so cold elastic wires should be selected to ensure its normal operation; ABS harnesses require high temperature conditions, generally choose a high temperature environment of 150-200℃, a hard insulation layer, wear resistance, but more than 133 stranded wires should be selected.

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