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With the increasing functions of commercial vehicle electrical appliances, there are many varieties, rich configurations, various combinations of wheelbase, engine, transmission, etc., and most of them are produced in small batches, which leads to the multiplication of varieties of commercial vehicle wiring harnesses. Therefore, the cost of wiring harnesses is high, it is difficult to manage, and the maintenance of after-sales accessories is inconvenient. Moreover, wire harness manufacturers, like Kable-X, need to change process tools from time to time, which affects the delivery cycle. Commercial vehicle wiring looms are mainly divided into two categories: cab Wiring Harness and chassis wiring harness. Cab harness mainly includes: dashboard harness, floor harness, ceiling harness, door harness, cowl harness, additional harness, etc. Chassis harness mainly includes: frame harness, engine harness, post-treatment harness, headlamp harness and other additional harnesses.
1 The Main Reason for the Increase of Harness Varieties
1) Definition differences of the functional configuration of the whole vehicle's electrical appliances, such as electric rearview mirror, environmental monitoring, MP3/MP5, LED and other optional functions.
2) Changes in the overall layout of the whole vehicle, mainly including the relative positions of battery box, post-processor, urea tank (national IV or above models), etc. in the layout of the whole vehicle.
3) The definition changes of the whole vehicle configuration, mainly the differences of transmission, engine and braking system, etc.
2 Several Ways of Optimal Design of Wire Harness
1) Principle Design Optimization
Through the optimization of principle design, it is fundamentally achieved that the configuration changes of cab and chassis have no correlation, that is, they do not affect each other. For example, through VCU vehicle controller, cab harness is compatible with Cummins engine, Weichai engine and Yuchai engine, and cab harness replacement and variety increase caused by engine changes are avoided.
2) Development and Optimization of Electrical Components
In order to meet different configuration requirements and variety classification, there are multiple suppliers or different versions of the same electrical parts in the OEM. Therefore, when the same component is developed, it is required to unify its stitches and definitions, so as to reduce the variety increase of wiring harness. For example, some main engine factory instruments have 4.8-inch LCD screen, 5.2-inch large-screen LCD screen and full LCD screen to locate the whole vehicle. Because there are different suppliers, there are differences in PCB board structure and pin definition during the design period. In order to reduce the improvement of instrument panel harness varieties, all suppliers are required to keep all the pin and pin definitions of parts consistent.
3) Function Reservation Design
Due to the difference of configuration, in order to realize the general design of wiring harness, some functions need to be reserved, so as to realize the consistency of wiring harness and reduce the variety of wiring harness. For example, there are two models A and B with the same layout and the same configuration requirements except for different engines in a certain engine factory.
As there is one more exhaust brake solenoid valve on the frame harness of car A with Weichai engine compared with that of car B with Xi 'an Cummins engine, the rest are all the same. In order to reduce the variety of harness, car B can use the frame harness of car A, and the reserved Connector of exhaust brake solenoid valve can be blocked. When car A is in use, remove the cover and recycle it.
4) Design of Transition Line
Due to the difference of configuration and layout, the variety of main harness is reduced, and the transition line is increased to realize the function of the whole vehicle. Taking a 6X4 tractor in a main engine factory as an example, according to the configuration requirement analysis, this model has the optional requirement of side protection. Because of the position difference and assembly requirement of the side marker lamps, when matching the side protection, the transition line of the side marker lamps is added to realize the universality of the frame harness.
5) Design of Wiring Harness Tying Back
Some harnesses are designed to be tied back, so as to realize the generalization of harnesses. Take model A and model B of an engine factory as an example. Model A is always longer than model B, that is, the two models are all the same in layout position, wheelbase and configuration except for the difference in the length from the tail beam of the frame to the center of the rear axle in X direction. When the frame harness is designed to match the A model, when the B model uses the A model frame harness, it can be tied back at the inner side of the longitudinal beam.
6) Classification of Harness Varieties
The relevant parts and functions are classified into harness varieties, so as to avoid the change of harness caused by different partial configurations. Take the models A and B of a main engine factory as an example. The model B is based on the model A by changing the engine manufacturer, that is, the layout, wheelbase, configuration, etc. are all the same except for the different engines. By uniformly dividing the functions related to the engine into the engine and the after-treatment harness, the rest of the main harnesses can be used in common, and the change of the frame harness can be avoided.
7) Modular Design
For some vehicles which are difficult to assemble, but the local layout forms are consistent, and basically the same type of vehicles are adopted, the sectional modular design can be carried out. For example, the modular design of post-processor harness integration improves the feasibility of harness assembly.
3 Concluding Remarks
In this paper, some methods and ideas are provided for the design and development of commercial vehicle wiring harness, so as to reduce the cost and types of commercial vehicle wiring harness, improve the feasibility of developing and assembling commercial vehicle wiring harness, shorten the supply cycle, and reduce the investment and development of wiring harness suppliers' tooling. In the later design, the design and development should be combined with specific conditions, including cost, output, cycle, assembly, after-sales, and other factors, so as to finally reach the optimal state of Wire Harness design and development.
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