What are the harness manufacturing processes?

Automobile wire, also known as low-voltage wire, is different from ordinary household wire. General household wires are copper single core wires with certain hardness. Automobile wires are copper multi core flexible wires. Some flexible wires are as thin as hair. Several or even dozens of flexible copper wires are wrapped in plastic insulating tubes (PVC), which are soft and not easy to break.
Because of the particularity of automobile operation, the process of automobile harness processing is also more special than other general harnesses.
The systems for manufacturing automotive wiring harnesses are roughly divided into two categories:
1. Different from European and American countries, including China:
TS16949 system is used to control the manufacturing process.
2. Mainly Japan:
For example, Toyota and Honda have their own systems to operate the manufacturing process.
With the increase of automobile functions and the wide application of electronic control skills, there will be more and more electrical parts, more and more wires, and the harness will become thicker and heavier. Therefore, advanced vehicles have introduced can bus equipment and selected multi-channel transmission system. Compared with the traditional wire harness, the multi-channel transmission equipment greatly reduces the number of wires and connectors, making the wiring easier.
Commonly used
Common standards for wires in automobile harness include wires with nominal cross-sectional areas of 0.5, 0.75, 1.0, 1.5, 2.0, 2.5, 4.0 and 6.0 mm2 (the nominal cross-sectional areas commonly used in Japanese vehicles are 0.5, 0.85, 1.25, 2.0, 2.5, 4.0 and 6.0 mm2). They all have allowable load current values and are equipped with wires for electrical equipment with different powers. Taking the whole vehicle harness as an example, the 0.5 standard wire is applicable to surface lights, indicator lights, door lights, ceiling lights, etc; 0.75 standard line is applicable to license plate lights, front and rear small lights, brake lights, etc; 1.0 standard line is applicable to turn signal lamp, fog lamp, etc; 1.5 the standard line is applicable to headlights, horns, etc; Main power lines such as generator armature line, grounding wire, etc. require 2.5 to 4 mm2 wires. This only means that for ordinary cars, the key depends on the maximum current value of the load. For example, the grounding wire and positive power line of the battery are special car wires used alone. Their wire diameters are relatively large, at least more than ten square millimeters. These "Big Mac" wires will not be incorporated into the main harness.
put
Before placing the harness, make the harness diagram in advance. The harness diagram is different from the circuit schematic diagram. The circuit schematic diagram is an image describing the connection between various electrical parts. It does not reflect how the electrical parts are connected with each other, and is not affected by the standard shape of various electrical components and the spacing between them. The harness diagram must not only take into account the standard shape of each electrical component and the spacing between them, but also reflect how the electrical components are connected to each other.
After the technicians of the harness factory made the harness wiring board according to the harness diagram, the workers cut and arranged the wiring according to the rules of the wiring board. The main harness of the whole vehicle is generally divided into engine (combustion, EFI, power generation, starting), surface, lighting, air conditioning, auxiliary appliances and other parts, including main harness and branch harness. A whole vehicle main harness has multiple branch harnesses, just like a tree pole and a branch. The main harness of the whole vehicle often takes the surface panel as the central part and extends forward and backward. For reasons such as long contact or convenient equipment, the harness of some cars is divided into front harness (including surface, engine, front lamp assembly, air conditioner and battery), rear harness (tail lamp assembly, license plate lamp and trunk lamp), roof harness (door, ceiling lamp and audio horn), etc. Each end of the harness will be marked with numbers and letters to indicate the wire connection policy. The operator can see that the mark can be correctly connected to the corresponding wires and electrical equipment, which is particularly useful when repairing or replacing the harness. Together, the color of wire is divided into monochrome wire and two-color wire. The purpose of color also has rules. Generally, it is the standard set by the car factory. China's operation standards only regulate the main color. For example, black is specially used for grounding wire, and red is used for power wire, which can not be thick.
The harness is wrapped with woven thread or plastic adhesive tape. For safety, processing and repair convenience, the woven thread package has been selected and is now wrapped with adhesive plastic tape. For the connection between harness and harness and between harness and electrical parts, connector or lug shall be selected. The connector is made of plastic and is divided into plug and socket. The wire harness is connected with the wire harness with a connector, and the connection between the wire harness and electrical parts is connected with a connector or lug.
Material Science:
The automobile also has strict requirements for materials:
Including its electrical function, material emission, temperature resistance, etc., the requirements are higher than the general harness, especially those related to safety: for example, the harness of important components such as direction control system and brake, the requirements are more stringent.