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The wire length calculated by process directly affects the processing progress and the performance of Wire Harness, and the wire length is often short in processing. The size is too short, which does not meet the requirements of drawings and loading. It takes time and effort for processing personnel to lengthen or change lines. If the wiring harness is too long, it will be difficult to arrange and bulge, which will cause the appearance of the wiring loom to be poor. After loading, eddy current and heat will affect the service life of the wire harness. It can be seen that the size of the lower wire is very important to the wire harness process. The factors that affect the size of the lower wire harness process will be discussed from several aspects.
Different Wiring Harness drawings and special wiring harness products (such as high-voltage lines) of different OEMs have different definitions of branch measurement points: A, it is required to measure from the end face of the wire inlet end of the Connector; B it is required to measure from the end face of the plug-in end of the connector. Given the same length of the two measurement methods, whether the size of the connector is included in the branch will lead to the difference of the length of the down line. Different definitions of measuring points directly affect the length of branches, so it is necessary to fully understand the measuring points of design drawings when calculating the length of process.
Head size is common in wiring harness drawings, and different design drawings define it differently.
(1) The head size can be regarded as the loss of the plug wire inside the sheath, and this length is not included in the branch length;
(2) The head length is the buffer size between the wrapping material and the connector, and the branch length includes the head length;
(3) With the tail clip, the tail clip needs to be stuck between the connector and the wrapping material, and generally, the head length is the internal loss of the tail clip and the connector.
To sum up, whether the head size is the internal loss of connector and tail clamp directly affects the branch length. Generally, for connectors with less than 8 holes, the line length with tail clip is less than 5cm, and when the head length is less than 5cm, it is regarded as the internal loss of the connector, so it is unnecessary to increase the branch length.
When the wires are assembled into wire harness products, there should be no tension, and the stress of a single wire should be natural, without stretching and folding back. Therefore, the length calculated only by the drawings does not meet the actual processing requirements, and should be moderately lengthened. In addition, at the present stage, most of the wire harness processing is in the form of hand-made, so it is inevitable that the length loss will occur. Therefore, the length of the downline should be increased by an appropriate allowance based on the length of the drawing.
The increased allowance is closely related to the length, wire and wire diameter of the wire. In general, the longer the length, the greater the loss and the greater the lengthened allowance. The larger the wire diameter, the less likely it is to bend in the wire harness, the smaller the loss and the smaller the allowance. However, different wires, such as shielded wire, camera wire and ABS wire, have a larger wire diameter than ordinary wires, so the loss is small and the allowance is small. Due to the different functions and load currents of connecting appliances, wires with different wires and diameters need to be selected, and the lengthened allowance of the wires is different. Therefore, it takes several times of allowance optimization and experience accumulation to hang a wire harness with perfect size.
Among the wiring harness connectors, there is a special connector, and both the left and right sides can be wired. Because the connector is large, when the left side goes out, the length of the wire near the left pin is different by one connector length from that of the right pin, and vice versa. Therefore, it is necessary to determine the outlet direction of the connector according to the loading situation and demand, so as to solve such problems.
Wrapping materials of wire harness generally include corrugated pipe, PVC pipe, nylon sleeve, tape winding and so on. Different wiring harness products are processed with different wrapping materials due to different installation positions and sales areas, for Kable-X.
(1) Take corrugated pipes as an example: corrugated pipes can be divided into closed pipes and open pipes according to the processing requirements. When there are many trunk wires in the closed pipes, there are problems of difficult threading and processing. In addition, it is inevitable that the wires will be entangled in the closed pipes, so the loss length of the closed pipes is more than that of the open pipes, so more allowance should be added.
(2) Tape winding can be divided into dense winding, point winding and flower winding. Tight wrapping needs to be all wrapped, and the stress of the wire is tighter, and the loss of length is greater than that of point wrapping and flower wrapping. In this case, more allowance should be added. It can be seen that different wrapping materials also have different requirements for length.
Branch manifolds and trunking are located at the branch points, which are used to fix the direction of the branches of the wiring harness. When in use, it is necessary to match the appropriate pipe according to the aperture, and fix the direction by clamping the bellows. There is length loss in the branch manifold and trunking, so the setting of allowance should also be considered when in use.
Connector is the central structure connecting wires and electrical appliances, the main component to realize the function of wire harness, and the most expensive raw material in wire harness. It is very important to know the connector used clearly. When the wire is inserted into the connector after crimping the terminal, a part of its length is lost inside the connector, and the connector with the tail clip will increase the lost wire length. Therefore, the rationality of the allowance setting is very important to the length of the wire harness. When calculating the process length, it is necessary to know the wire feeding length of the connector and the tail clip first, and include it in the offline size.
In the process of wiring harness, there are many wires that need to be conducted. In the process of wiring harness, conductor crimping and ultrasonic welding are commonly used to conduct the wires. The length of the welding area and conductor crimping area is about 2cm, so the loss here should be taken into account when calculating the size of the lower conductor, especially when there are multiple conduction points, the influence on the line length will become more and more important.
The direction of the wires in the harness is not the same, the simplest one is straight without turning, and this kind of length loss is the smallest. The more turns of the wire, the more the length of the wire is consumed at the bend, and the longer the overall downline length is. For this kind of wire, extra allowance should be added to ensure its smooth transition from the bend.
With the development of automobile technology and the arrival of intelligent manufacturing, various functions of automobiles are becoming more and more abundant. As a bridge between the functions of various electrical appliances, the future development of wiring harness will be full of challenges, and its composition will become more and more complicated. All kinds of wires with new requirements will come one after another, and it is increasingly difficult for wiring harness technicians to analyze and calculate the length of offline wires from various factors. In this paper, the most basic wire length of wire harness is taken as the theme, and the factors affecting the size of the lower wire harness are analyzed from several aspects to ensure the accuracy of the lower wire length.
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