Design process for automotive wiring harness circuits

Automotive wiring harness is an important part of automotive electrical system. In the design process of automotive wiring harness circuit, it is necessary to consider the selection of wires simultaneously. According to many years' working experience, this paper expounds the wire from seven aspects: type, parts requirement characteristics, wire number, wire color, wire diameter, lightweight and matching with fuse wire.

1. The wire type is also called the wire type. During the wire harness layout design process, engineers will choose different wire types according to different functions. Since cars use 12V batteries for power supply, car wires are also called low-voltage wires. 2. Characteristics: Heat resistance: According to the working environment temperature of the wiring harness wires, wires with different temperature resistance levels are selected. The wires of the passenger compartment can be selected with a temperature resistance level of 90 ℃; The wiring harness of the engine compartment can select wires with a temperature resistance level of 180 ℃; The conductors crossing the above two areas should be selected whose temperature resistance grade meets the temperature requirements of the two areas at the same time. The temperature resistance requirements of the area can be obtained through the temperature field, and then the selected conductor type can be determined from the temperature resistance grade of each conductor. 3. The wire number is the number of the wire in the wire harness drawing. It is a name characteristic that distinguishes the wires from each other in the wire harness drawing. The number of wires in the wiring harness drawing generally corresponds to the electrical circuit number in the electrical schematic diagram of the whole vehicle circuit. At present, there is no uniform standard for the number of wires in the wiring harness. 4. Line color: With the increase of automotive electrical equipment, the number of wires in the wire harness is also increasing. In order to facilitate the identification and detection of automotive electrical equipment, different line colors are usually used for low-voltage wires in the wire harness. At present, there are generally two ways when selecting wiring: single-color wire and two-color wire. 5. The wire diameter is the nominal cross section of the guide wire. Whether the wire diameter is reasonable or not is not only related to the safety of the wire harness, but also can effectively reduce the cost. 6. Lightweight selection of wires: Consider lightweight wiring harness when selecting the cross-sectional area of wires. The outer insulation of wires is also constantly being innovated, so that the quality of wires can be reduced and the performance can be improved. 7. Matching of wire and fuse wire: The fuse wire is a thermal energy responsive element, which is intentionally designed and manufactured to be the weakest part of the circuit in order to protect the wire harness. After selecting the fuse component of the circuit, the wire specification of the circuit connected to the fuse should be confirmed. The selection principle is that the current-time characteristic of the wire must be higher than the current-time characteristic curve of the fuse connected in series.

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