Principles to be considered in the design of automotive wiring harnesses

Because there are more and more electronic control units in the automobile, the data transmission of each electronic control unit is also increasing by multiples, which requires the automobile wiring harness to have a better information transmission function, and then leads to the design of the automobile wiring harness becoming more and more complex. Draw the electrical schematic diagram and circuit diagram of the whole vehicle; distribute the energy of each electrical subsystem and circuit according to the electrical schematic diagram; determine the wiring form of the harness; draw the two-dimensional harness diagram and three-dimensional harness layout diagram; these harness design steps must be carefully considered. In addition, there are also some wiring harness design principles that should be paid attention to, so as to make the automotive wiring harness design comprehensive and meticulous, without any mistakes. 1. The harness between two relatively moving parts must be fixed on each part, and the connection length of the harness should be more than 25mm longer than the maximum replacement distance of the two parts. II. All wire harnesses arranged near moving parts shall have a clearance of at least 50mm. Under the condition of the maximum assembly tolerance of the harness, the clearance between the harness installed on the drive system and the parts not installed on the drive system shall be at least 19mm. Under the condition of the maximum assembly tolerance of the harness, under other operating conditions, this clearance is to ensure the full range of movement of the moving parts/assembly. III. The minimum clearance between the harness and the adjacent parts not associated with the harness is 6mm, unless the harness has been fixed on this part, or there is a shelter between the harness and the nearby moving parts. IV. Manual assembly is required. The harness fixing parts to be pressed into the seat, as well as the holes and slots with wire clips to be inserted, shall be designed according to the following maximum installation force: for the fixing parts pressed by fingers, the operating force shall be 45 N; for the fixing parts pressed by hands, the operating force shall be 75 N. 5. Automotive harness branches must have enough slack (more than 25mm at the minimum length of the harness) so that they do not add load to the connected sensors or others. VI. In order to prevent the grounding strap from damaging any harness on the trunk, the minimum clearance from the grounding strap on the trunk of the harness to the trunk of the harness shall be maintained at 25mm during loading. VII. In order to ensure the normal function of the rubber plug on the automotive harness, the plugged mounting hole must meet the relevant requirements. VIII. The rubber plug shall be designed to be completely assembled into the sheet metal hole under the installation force of less than 100 N. IX. The noise generated by the harness to the headrest of the driver's seat shall not be greater than 50dB, and the frequency shall be 50 ~ 15000 Hz. The function of automotive wiring harness in the vehicle is to transmit or exchange the power signal or data signal of the electrical system to achieve the functions and requirements of the electrical system. If the automobile wiring harness is not well designed and the functions of each part can not be organically combined, the wiring harness may become a frequent link of automobile failure. Therefore, wiring harness designers should carefully carry out each step of automotive wiring harness design, consider many principles that should be paid attention to, and ensure the rationality and reliability of automotive wiring harness design.

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