Suggestions on improving the quality of airbag wiring harness

Analysis of the harness of 1 airbag，

The airbag harness is composed of wires, connectors and wrapping tape, which is an important component connecting various electric appliances and electronic equipment of the car, and is the main network body of the car circuit. The initial condition of the car is simple and the mechanical control is the dominant position. The electric road harness is only a part of the whole vehicle, which has not been paid attention to. The evaluation of its skill quality is only the circuit conduction or not. The processing technology of the electric road harness is the post falling process of the wring, welding and bolting, and its connection is not reliable, interchangeable, repairable and so on. With the addition of car electrical system, the terminal electrical equipment is added directly, so the signal transmission can also be challenged. The solution is to add wire circuit, which inevitably increases the wire, connector, sensor, etc., and the component and volume of the electric road bundle also reach the scope that the car can not bear. Therefore, the development direction of airbag harness is to improve the signal transmission ability and reduce the component of the passenger car cable harness.

Analysis of the common faults of airbag harness
Combined with the author's practical experience, the author thinks that the product design and development process and production process of airbag harness will have an impact on the quality of the harness. The following analysis is made on the common problems and reasons of airbag harness: (1) when a car steps on the accelerator pedal, the accelerator does not respond, the speed cannot be increased, the engine jitter and exhaust pipe have black smoke. It is judged that the harness is poor in touch. After replacing the engine harness, all kinds of defects shall be removed. After investigation, the above problems are caused by the poor compression connection at the tail of the terminal in the engine ECU connector in the engine harness, and the copper wire leakage and the terminal touch at the adjacent hole position, resulting in short circuit. The first and direct reason is the short circuit of the harness. The second, the root cause is that the harness production process is not well controlled and the terminal crimping is poor.



3 suggestions for improving the quality of airbag harness
Strengthen the inspection of the original data
To improve the quality of airbag harness, the first requirement is to strengthen the inspection of the original data according to the relevant specifications of airbag harness.
(1) Check the wires. In the original data of airbag harness, the wire is used most, and the whole manufacturing process and operation process of the harness touch the wire, so the quality control of the wire is the most important. The main parameters and functional indexes of the wire are: appearance structure, initial elongation, high temperature aging elongation, high temperature resistance, cold bending resistance, flame retardant, oil resistance, wear resistance, kneading resistance, etc. The parameters of different specifications such as structure scale, insulation material and thickness are different. The intention of controlling appearance structure is to control wires to meet the corresponding specifications and color requirements. When a function index of the wire fails to meet the requirements (failure), the relevant functions of the harness will decrease.


(2) Check the connector. The car connector (including terminal and sheath) is the most basic unit of the harness, and also the center of the reliable transmission and connection of the electrical signal. It can also be said that the harness is a connector connected with wires. It can be seen that the quality of the connector is important to the quality of airbag harness. The full function test of the terminal includes the insertion force of the plug-in sheath, the holding force of the connector in the sheath, the insertion force and pull-out force of the plug, the touch resistance, the temperature change rapidly, the temperature rise test, the current cycle, the temperature and humidity cycle, the combined temperature vibration, the tensile strength of the conductor adjacent, the corrosion of the active gas and the salt spray test. The full function experiment of sheath includes terminal bonding (detaching) force, wire attachment tensile strength, terminal winding strength, terminal bonding force between terminal and sheath, terminal persistence, sealing, waterproof, skid resistance of connector, over current bearing, repeated plug durability, impact resistance, sheath detachment force, coupling (detaching) force, locking force /Unlocking force, low voltage current tolerance, frost resistance, current discharge and voltage drop.

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