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Automotive Wiring Harness is an indispensable part of the automobile, and it is also the "nervous system", which is the wiring component of the automobile circuit to connect various electrical equipment. In order to ensure the safe operation of the vehicle, it is necessary to scientifically design the whole vehicle wiring harness system, improve the reliability of the whole vehicle wiring harness, and realize the improvement of the safety and durability of the whole vehicle wiring harness system. This paper mainly introduces the principle of three-dimensional layout of vehicle wiring harness, and elaborates the fixing method of wiring harness in detail. According to the design experience of the main three-dimensional wiring harness layout personnel, it provides some reference and help for the three-dimensional layout and design ideas of low-voltage wiring harness.
The three-dimensional design of the Wire Harness should be simple in structure, convenient to assemble and disassemble, beautiful in layout, good in fixation and protection, etc. At the same time, the wire harness layout should consider the principle of the wire harness, so as to make the wire harness path shortest as possible; Try to adopt modular design in wiring harness to reduce loops. The main layout principles include wiring harness reliability, wiring harness aesthetics, assembly and maintenance, electromagnetic interference protection, etc.
2.1 Reliability
Vehicle harness reliability requirements:
(1) When wiring harness is arranged, the wiring should be hidden as far as possible, and it should not exceed the rigid outer contour of parts, generally along the inner edges and corners of the car body and frame;
(2) The diameter of the wire harness in the mathematical model should be consistent with the actual wire harness. On the one hand, the specific outer diameter of the outer cladding should be considered, and on the other hand, the wire diameter under the highest configuration should be calculated; When the trunk can't be evaluated in detail, the maximum diameter calculated in principle or the existing vehicle type can be evaluated;
(3) At the part with water risk, the outlet direction of the Connector tail cannot face upwards. When the outlet direction is horizontal, the tail harness should be guided downwards first, and the water guide bend should be designed to prevent the connector from becoming the lowest point of the branch;
(4) When the cab harness passes through the via hole, it needs to be protected by a rubber sleeve; When passing through parts with sharp corners and sharp surfaces, the surface of parts should be covered with protective pads or rubber protection to avoid damage to the surface of wiring harness;
(5) The wiring harness shall be arranged to avoid the parts that cause damage to the surface of the wiring harness, such as the frame, bracket, bolt head and the edges of parts, and the distance between the wiring harness and the parts shall be 10mm; The wiring harness should avoid high-temperature parts such as engine exhaust pipe, supercharger and air compressor, and a heat insulation board should be set between the wiring harness and the high-temperature parts with a temperature of ≥200℃ (such as engine exhaust pipe), and the distance between the wiring harness and the heat insulation board should be ≥ 50mm. Distance from air compressor pipeline ≥50mm. Harness should avoid rotating parts (such as fan, pulley, transmission shaft, external fan blades of generator, etc.), and the distance between harness and relative rotating parts is ≥ 50mm;
(6) The tail harness of the connector needs to be fixed within ≤120mm, but special parts such as MP5, cigarette lighter and other rear fittings need special treatment.
2.2 Aesthetics
Aesthetic requirements of vehicle harness:
(1) The direction of the wiring harness should be consistent with that of the attachment, and it should be arranged horizontally and vertically in the projection direction, so as to avoid oblique arrangement as far as possible;
(2) The design colors of the whole vehicle wiring harness should be coordinated, and generally, dark connectors are recommended for the exterior of the vehicle body; Wire Harness can't be wound or cross-arranged;
(3) The cable harness and the surrounding wiring harnesses, water pipes, gas pipes, oil pipes, etc. are as unified as possible, and the overall appearance is beautiful;
(4) The selection of wiring harness wrapping materials should consider aesthetics, and the color should not be messy.
2.3 Assembly and Maintenance
Requirements for assembly and overhaul of vehicle harness:
(1) It is recommended that the connector of the wiring harness be arranged in a position that can be touched by the hand, or that the connector can be touched and plugged after simply disassembling some parts;
(2) It is not recommended to arrange connectors with the same model in the adjacent positions to avoid wrong insertion in the assembly process, which may damage the wiring harness and electrical appliances;
(3) Harness accessories such as cable ties and buckles on the harness should be brought on the harness as far as possible, so as to avoid field assembly affecting the production rhythm;
(4) When the chassis harness passes through the first beam, a guide bracket should be designed near the beam to protect the harness from passing through;
(5) The chassis wiring harness shall be marked at the first beam, wiring harness threading hole, front axle centerline and flywheel housing to facilitate wiring harness installation;
(6) Check the assembly tool space of bolts on the wiring harness, and check with electric tools;
(7) It is necessary to know the assembly process, tooling, etc. of the wiring harness, and consider the influence of tooling on the wiring harness design.
3.1 Connector Fixing Scheme
The upper harness connector is mainly fixed by clamping nails, piercing sheet metal and bolting.
(1) Generally, the clamping nail is suitable for sheet metal holes of φ 6mm, φ Φ7mm and 7mm×12mm. For large space, generally, connectors with φ Φ6mm and 7mm clips are selected. For the wiring harness direction that needs to be strictly limited, the connector can choose φ Φ7mm×12mm clip, which can prevent the wire harness from twisting after the installation, and the use effect is good, and it has strong fixing stability after the installation.
(2) After the connector is fixed through the sheet metal, use the fixing card to fix it.
This kind of connector can be fixed firmly, which requires high reliability, so this kind of fixing method can be selected.
(3) The connector is clamped by the fixing plate and matched with the sheet metal bracket through bolt connection. This fixing method is suitable for fixing connectors with many connector holes, and it is reliable.
3.2 Harness Fixing Scheme
3.2.1 Sheet Metal Bracket Is Fixed with Tie.
The wire harness bracket is connected with the frame or the engine by bolts, and then the wire harness and bracket are tied with a cable tie. Generally, the cable tie holes are 5mm ×10mm slotted holes. In order to ensure the mechanical strength of the bracket, it is necessary to add reinforcing ribs.
3.2.2 Tie Fixing
There are many kinds of fixing ties for the harness. For those who need to keep a set distance between the fixing point and the harness assembly, or to avoid the natural sagging of the harness, these products can be preferred, and the fixing method is simple. Cable ties mainly include sheet metal cards, fir-tree cable ties, T-cards, etc.
Sheet metal clamp: This type of cable tie is suitable for fixing on the material which is difficult to open holes or the panel with large thickness. Because it will damage the paint surface of the car body, it should be carefully selected for the position which requires high appearance. If it must be used, it is recommended to choose the plastic type without damaging the paint surface of the car body.
Tree-shaped cable ties: mainly used with round holes with diameters of 7mm, 9mm, 11mm and 13mm.
T-card: It is mainly used in places where the wiring space of the harness is narrow due to the installation of exterior decoration or where the wiring of the harness itself is not easy to punch holes.
3.2.3 Fixation of Plastic Trunking
Sometimes, due to the limitation of wiring harness layout space, it is necessary to develop a separate plastic bracket to protect and fix the wiring harness. Generally, PA66 material is adopted, and this scheme will greatly reduce the wear of the harness and avoid the after-sales wear of the harness due to wear.
The layout of automotive wiring harness is of great significance to the stable operation of automotive electronic and electrical systems. In the layout of automotive wiring harness, the principles of easy assembly, easy maintenance, safety and stability should be followed, and the wiring harness layout should be rationally planned according to the characteristics of the automobile itself, so as to continuously improve its scientificity and rationality. Through the discussion and application examples of wiring harness layout principle and fixing method, the wear of wiring harness is avoided in advance, which plays a certain reference role in wiring harness design of us Kable-X.
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