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The door wire harness is a part of the whole vehicle wiring harness, and it is the channel connecting the power supply and electrical components. In this paper, the function of the door cable harness is analyzed with examples, and the layout principle of the door wiring loom is elaborated in detail from the aspects of fixing mode, harness direction, waterproof measures, antimagnetic measures, loss prevention measures, selection and matching of connectors, etc., so as to achieve the purpose of optimizing the layout and function of the door harness.
Automobile electrical equipment is connected with power supply, control switch and protection device through wires. Wires are the basic components of automobile electrical circuit, and Wire Harness is made up of wires with the same direction. Bundling multiple wires into a wire harness can make the circuit not messy, facilitate installation, and play a role in protecting wires. The power supply and all kinds of electrical parts on the car are physically connected by wiring harnesses, which are all over the car. Automobile door system is an important set of functional parts, which requires high Wiring Harness system. The door wiring harness system is also one of the more complex wiring harness systems on automobiles, so special attention should be paid to wiring harness layout.
1 Introduction to Door Harness System
Automobile door is one of the important automobile functional parts, and there are more and more requirements for the electrical equipment configuration and functions on the door. Therefore, the wiring harness connecting all the electrical equipment is becoming more and more complex, which has become a frequent link of contemporary automobile failures. Therefore, it has attracted more and more attention in automobile design and manufacturing. Automobile doors are integrated with important electrical components such as switches, buttons, glass lifters, horns, door locks, etc., and the door wiring harness should meet the working connection requirements of these components.
The wiring harness of the door is distributed on the wet and dry sides of the door, with many branches and many fixing points. The effective arrangement of the wiring harness of the door is an important link to ensure the realization of the function. The structure of typical car door harness includes branches and connectors of important electrical components.
2 Layout Principles of Door Harness
In order to ensure the rationality of the design and safety of the door harness, the layout of the harness designed by us, Kable-X, should follow the following principles.
1) Strong assembly operability. Use clamp springs or buckles to fix the harness to prevent the harness from falling off. When assembling, just press the buckles on the corresponding holes. Use as few buckles as possible to fix as many harnesses as possible, so as to reduce the holes in the car body.
2) In general, it is necessary to add a fixed point at a distance of 120 mm from the wiring harness Connector, in order to minimize the load caused by the vibration and quality of the wiring harness borne by the terminals in the connector.
3) Within the maximum tolerance required for wire harness assembly, there should be enough gap between the wire harness arranged near the moving parts, and this gap is determined by the amount of movement of the moving parts. Within the maximum tolerance required for harness assembly, if the harness is not fixed on the corresponding parts, it should have at least 6mm clearance from the stationary parts.
4) When wiring the door harness, try to stay away from the heating area and moving parts area.
5) For the outlet position of automobile moving parts and connectors, sufficient wire length shall be reserved according to the vibration amplitude of automobile parts and the maximum movement stroke of moving parts, so as to avoid the wire harness bearing tensile force or tension. When wiring harness branches are laid out, the chosen layout place should be as wide as possible, and the length allowance should be as long as possible, which is generally larger than 25 mm when the wiring harness is slack, so as to prevent the moving parts from causing wear or tensile stress damage to the wiring harness during the movement.
6) In areas with strong electromagnetic interference, it is necessary to pay attention to adding anti-magnetic protection to the wiring harness, and special wires such as twisted pair or shielded wire can also be used.
7) Harness should avoid wiring from sharp objects, metal frame edges, welding seams, and fixing holes on the car body, especially at corners. When bypassing acute corners or passing through holes, rubber or felt mats or protective covers should be used for key protection to prevent functional failure caused by harness wear.
8) All connectors must be matched, and good contact should be kept between connectors.
9) The wiring harness shall be arranged on the dry side of the door as far as possible to prevent the influence of water leakage on the wiring harness.
3 Layout Example of Door Harness
At present, there are two ways to install the door wire harness, one is that the wire harness is directly fixed on the door sheet metal hole; The other is integrated on the door module and installed on the sheet metal through the door module. Japanese and Korean cars and independent brands mostly adopt the first fixing method, while European and American cars mostly adopt the second one.
Taking the layout of the door harness of a certain vehicle as an example, the layout principle and application of the door harness are explained. This vehicle harness is arranged on the door module.
1) This model uses the cable tie buckle or clip spring to fix the harness, which is very simple. The position of the cable tie can be adjusted according to the thickness of the harness, so as to ensure the firmness of fixing, which plays a role in preventing the harness from shaking during the running of the vehicle. Moreover, the installation and disassembly are convenient.
2) The route of the harness is smooth, with no dead angle or bending, thus avoiding the breakage of the harness. There is a certain distance from the heating area and the moving area of the motor harness, which is generally required to be more than 20 mm. The distance of this model is more than 35 mm, which reserves enough space for the layout of connectors to avoid interference and heating. The arrangement spacing of cable ties is about 120mm, which not only ensures the firmness of fixing, but also avoids the repetition and waste of installation. Moreover, most of the wiring harnesses of this car are arranged on the dry side of the door, and it is difficult for external water to enter here, thus minimizing the risk of water intrusion into the wiring harness.
3) Waterproof measures were taken when the harness passed through the hole, rubber plugs were used to prevent water leakage, and waterproof tape was added to the connection area where the harness extended out of the rubber plugs. The part where the harness passes through the door and connects with the car body is wrapped with a rubber plug. The shape of the rubber plug is designed according to the hole position and shape of the door sheet metal, and it is completely attached to the door sheet metal to prevent water from entering.
4) When the harness passes through the sharp hole, it is covered with foam to prevent the edge of the hole from scratching the harness, and a harness buckle is designed at the edge of the hole to prevent the harness from being scratched when the harness shakes.
5) Twisted pairs are used in the wiring harness, so that the electromagnetic fields induced in the twisted rings cancel each other out, and the interference of external electromagnetic fields on the twisted pairs and the crosstalk between the twisted pairs are reduced. When approaching electric appliances with large electromagnetic radiation such as door locks, add an anti-magnetic coating outside the conductor to ensure that the wire harness is not affected by electromagnetic radiation.
6) The connector shall be the glass lifter connector on the wiring harness. Before mass production, each connector on the wiring harness shall be strictly matched with the counterpart. The appropriate connector shall be selected according to the layout and function of PIN pins, so as to prevent the failure of the function caused by connector errors.
4 Summary
In a word, the door harness is the guarantee for the normal operation of the electrical components on the door, which connects the power supply with the switch, button, window lifter, horn, door lock and other important components. The layout of the door harness is directly related to the realization of the function of the harness and the safety of the electrical components. Therefore, when arranging the harness, it is necessary to consider the fixing method, harness direction, waterproof measures, antimagnetic measures, loss prevention measures, selection and matching of connectors, etc., so as to optimize the design and layout of the harness.
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Privacy statement: Your privacy is very important to Us. Our company promises not to disclose your personal information to any external company with out your explicit permission.