Basic Principles and Precautions for Automotive Wiring Harness Arrangement

When designing the three-dimensional direction of the automotive wiring harness, it is necessary to fully consider the electrical parts of the whole vehicle in combination with the specific conditions of the body sheet metal, frame and other wiring harness attachments. When designing the wiring harness layout, the wiring harness fixing shall also be considered. The fixing method and the number of fixing points shall be determined according to the hardware structure and the mechanical structure of the whole vehicle. When there are many controllers and they need to be arranged in a centralized way, the layout of the controller shall also be considered.

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1. Easy assembly In terms of assembly of automotive wiring harness layout, two aspects are mainly considered: the wiring harness itself is easy to assemble, and the wiring harness fixing structure is easy to assemble. The body of the 1、 harness assembly is easy to assemble. When arranging the automotive harness, try not to add too many processes to the assembly process of the whole vehicle. For different areas of the whole vehicle, the sub-assembly method can be used, such as instrument panel, door, roof, left and right body, etc. In addition, the characteristics of different areas shall be considered in the design process, and the designed wiring harness direction shall not affect the assembly of other vehicle parts; when the wiring harness passes through the hole, the diameter of the connector with the largest outer envelope diameter of the required through hole must be less than the diameter of the rice gold hole, otherwise the wiring harness cannot pass through. The harness fixing structure of 2、 is easy to assemble. When designing the harness fixing method and structure, the assembly must be considered. It is not allowed to add too many processes to the assembly process while pursuing the reliability of fixation. The following precautions are summarized according to the actual design experience. 1) Adopt a simple fixing method as far as possible, especially for the narrow space area, such as the wiring inside the door, the wiring between the white body and the interior, because of its narrow space, it should be fixed with plastic buckles or tape as far as possible. 2) The through hole rubber boot shall be designed to fit completely in the hole with an installation force of less than 100 N. 3) For the fixed parts that need to be pressed by fingers, the operating force is 45 N; Press-fit fixings by hand with an operating force of 75 N. 4) In the design process of harness fixing structure and relevant function box, the commonly used standard parts shall be used as far as possible, and the types of standard parts shall be as few as possible, and the use of special tools in assembly and maintenance shall be reduced through the preliminary design. 5) If the connector or harness fixing structure needs to pass through the cab during assembly, it is difficult for one person to complete the work independently if ordinary hexagon nuts and bolts are used as fasteners. At this time, it is generally considered to use welding nuts or self-tapping screws for fixation. 6) The fixing hole of the harness shall be opened in the plane area of the structural part as far as possible. When fixing on the curved surface, it is better to make a small plane on the structural part. 7) When arranging the electrical harness, consider the modular assembly of large assembly as far as possible to improve the assembly speed of the production line. For example, the transmission harness and the engine harness are assembled to the transmission and the engine body respectively, and then assembled to the chassis as a whole. 2. Good maintainability When arranging the electrical harness of the whole vehicle, we should pay attention to the after-sales maintenance. Good maintainability is reflected in the fact that when electrical system faults occur, the faults will be eliminated in the shortest time, and the faults will be eliminated without damage to other components caused by maintenance operations. If there is a problem with the harness or electrical parts, the disassembly should be simple, and the disassembly should not affect other unrelated parts, otherwise it will cause some unnecessary waste and increase the maintenance time. Therefore, in order to ensure good maintainability of the electrical system of the whole vehicle, the following aspects should be taken into account when arranging the electrical harness. 1) The harness connectors shall be arranged within reach as far as possible. 2) If the harness connector can only be inserted and pulled out with one hand, its opposite ends shall be fixed reliably. 3) The connectors at the same position shall be distinguished by color, size, internal positioning and other methods to prevent wrong insertion. 4) A certain length shall be reserved for the harness at the end of the connector to facilitate the insertion and extraction of the connector: it is recommended to reserve 80 ~ 100 mm for the harness at the switch end. For the combination instrument, audio, air conditioning panel, fuse box and other electrical devices with high maintenance rate, the rear harness shall be reserved to a length that is easy to insert and extract according to the installation position of the assembly. Figure 3 shows the harness of the function switch on the instrument panel of an off-road vehicle. In order to facilitate the disassembly and maintenance of the function switch, a margin of 100 mm is reserved for the branch of the function switch during the design of the harness.

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