What is an automotive wiring harness?

Automotive wires, also known as low-voltage wires, are different from ordinary household wires. Ordinary household wires are copper single-core wires with certain hardness. Automotive wires are copper multi-core flexible wires, some of which are as thin as hair, and several or even dozens of flexible copper wires are wrapped in plastic insulation tubes (polyvinyl chloride), which are soft and not easy to break. Because of the particularity of the automotive industry, the manufacturing process of automotive wiring harness is more special than other ordinary wiring harnesses.

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Automotive wiring harness manufacturing systems can be roughly divided into two categories: 1. Divided by European and American countries, including China: the use of IATF16949 system to control the manufacturing process. 2. Focus on Japan: Toyota and Honda have their own systems to control the manufacturing process. With the increase of automobile functions and the widespread application of electronic control technology, there are more and more electrical parts and wires, and the wiring harness becomes thicker and heavier. Therefore, advanced automobiles have introduced CAN bus configuration and adopted multiplex transmission system. Compared with the traditional wiring harness, the multi-channel transmission device greatly reduces the number of wires and connectors, making the wiring easier. The common specifications of wires in common automotive harnesses are wires with nominal cross-sectional areas of 0.5, 0.75, 1.0, 1.5, 2.0, 2.5, 4.0, 6.0 and other square millimeters (the nominal cross-sectional areas commonly used in Japanese cars are 0.5, 0.85, 1.25, 2.0, 2.5, 4.0, 6.0 and other square millimeters). Each of them has an allowable load current value and is equipped with wires for different power consumers. Taking the whole vehicle harness as an example, 0.5 specification wire is applicable to instrument lamp, indicator lamp, door lamp, ceiling lamp, etc.; 0.75 specification wire is applicable to license plate lamp, front and rear small lamp, brake lamp, etc.; 1.0 specification wire is applicable to steering lamp, fog lamp, etc.; 1.5 specification wire is applicable to headlamp, horn, etc.; Main power supply wires such as generator armature wires, grounding wires, etc. Require 2.5 to 4 mm square wires. This only refers to the general car, the key depends on the maximum current value of the load, such as the battery grounding wire, the positive power line is a special car wire used alone, their wire diameter is relatively large, at least more than ten square millimeters, these "Big Mac" wires will not be incorporated into the main harness. Before arranging the harness, draw the harness diagram in advance. The harness diagram is different from the circuit schematic diagram. The circuit schematic diagram is an image describing the relationship between the electrical parts, which does not reflect how the electrical components are connected to each other, and is not affected by the size and shape of the electrical components and the distance between them. The harness diagram must take into account the size and shape of each electrical component and the distance between them, and also reflect how the electrical components are connected to each other. After the technicians of the harness factory make the harness wiring board according to the harness drawing, the workers cut and arrange the wires according to the regulations of the wiring board. The main harness of the vehicle is generally divided into engine (ignition, EFI, power generation, starting), instrument, lighting, air conditioning, auxiliary electrical appliances and other parts, including main harness and branch harness. A main vehicle harness has multiple branch harnesses, just like tree poles and branches. The main wiring harness of the whole vehicle often takes the instrument panel as the core part and extends forward and backward. Due to length or assembly convenience, the wiring harness of some automobiles is divided into front wiring harness (including instrument, engine, headlight assembly, air conditioner, battery), rear wiring harness (taillight assembly, license plate lamp, trunk lamp), roof wiring harness (door, dome lamp, audio horn), etc. Each end of the harness will be marked with a symbol number and letter to indicate the connection object of the wire. The operator can see that the symbol can be correctly connected to the corresponding wire and electrical device, which is particularly useful when repairing or replacing the harness. At the same time, the color of the wire is divided into monochrome wire and two-color wire, and the use of the color is also stipulated, which is generally the standard set by the car factory. The industry standard of our country only stipulates the main color, for example, the single black is used for the grounding wire, and the red monochrome is used for the power cord, which should not be confused. The wire harness is wrapped with woven wire or plastic adhesive tape. For safety, processing and maintenance convenience, the woven wire wrapping has been eliminated, and now it is wrapped with adhesive plastic tape. Connectors or lugs shall be used for the connection between harnesses and between harnesses and electrical parts. The connector is made of plastic and is divided into a plug and a socket. Harnesses are connected by connectors, and the connection between harnesses and electrical components is made by connectors or lugs. Material Automotive wiring harness also has very strict requirements for materials, including its electrical performance, material emission, temperature resistance and so on, which are higher than the general wiring harness, especially those related to safety, such as the direction control system, brake and other important components of the wiring harness.

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