Функция и производство на кабелни снопове за автомобили

I. Core functions of automotive wiring harnesses
‌Power distribution and energy transmission‌
Provide stable power support for automotive electrical appliances (such as headlights, ECU-та) to ensure the normal operation of electrical equipment;
The transmission current range covers 0.5-6.0mm² wires to meet different power requirements34.
‌Signal interaction and control‌
Transmit sensor data (such as speed, temperature) to the control unit to achieve real-time monitoring of vehicle status;
Realize multi-channel signal transmission through the CAN bus to reduce the complexity of traditional wiring harnesses48.
‌Networked connection‌
Build a neural network for the vehicle electrical system and connect the entire vehicle’s electronic equipment (instruments, central control, safety systems) in series;
Support the high-speed data transmission requirements of on-board intelligent systems (such as ADAS).

II. Automotive wiring harness production process
Wire cutting: Cut the wire according to the drawing, the accuracy must be controlled at ±0.5mm, and the stripping length error must be ≤0.3mm;
Crimp: Match the terminal and the wire cross-sectional area, and set the crimping force range (such as 200-300N for 0.5mm² wire crimping force);
Pre-installation: Assemble the wiring harness branches in sections (such as engine compartment wiring harness, instrument wiring harness), and use bellows/tape protection;
General assembly: Integrate the branch wiring harnesses and fix them with buckles/brackets to avoid interference with moving parts25
Test: Perform continuity test (resistance ≤5mΩ), withstand voltage test (AC 500V/1min without breakdown) and waterproof test (IP67 level);

III. Материали и технически изисквания
Core materials
Тел: калайдисана медна тел (conductivity ≥98%), aluminum-magnesium alloy wire (lightweight scenario); ‌Insulation layer‌: high temperature resistant (-40℃ ~ 125 ℃) PVC/PE material, fluoroplastics are used in high frequency scenarios;
‌Connector‌: plug-in life ≥5,000 times, contact resistance ≤10mΩ (such as GH1.5/M12 series).
‌Technology trend‌
‌High voltage transmission‌: New energy vehicles use wires above 600V, with shielding layer to suppress electromagnetic interference;
‌Lightweight design‌: wire cross-sectional area optimization (such as aluminum instead of copper), integrated wiring harness layout7;
‌Automated production‌: laser welding replaces traditional soldering, with an accuracy of ±0.1mm and an efficiency increase of 30%.

IV. Typical application scenarios ‌Power system‌: The engine wiring harness needs to withstand high temperature vibration, and a metal wire box is used to fix the branch wiring harness;
‌Smart cockpit‌: The instrument panel wiring harness integrates CAN/LIN bus, supports multi-screen linkage and voice control;
‌Safety system‌: The seat belt pretensioner/airbag wiring harness needs to pass 100,000 bending tests to ensure the reliability of emergency triggering.

Забележка: During the design phase, wiring harness path planning (such as avoiding high-temperature exhaust pipes), EMC protection, and maintenance convenience must be considered simultaneously.

функция:
Power and Signal Transmission:
The wiring harness acts as a conduit, delivering electricity and signals from the battery to all electrical components, including the engine control unit (ECU), сензори, изпълнителни механизми, and other systems.
System Coordination:
It ensures that different electrical systems work together seamlessly, enabling functions like steering, braking, осветление, and infotainment.
Organization and Protection:
The harness organizes individual wires into a single, manageable unit, simplifying wiring and protecting wires from damage and environmental factors.
Space Optimization:
It helps conserve space within the vehicle by bundling wires and routing them efficiently.
Безопасност:
The harness plays a crucial role in ensuring vehicle safety by transmitting signals for critical functions like braking, steering, and airbag deployment.

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Production:
Design:
Wiring harnesses are typically designed for specific vehicle models and applications, considering factors like space constraints, wiring requirements, and safety standards.
Prototyping:
Prototypes are created to test the design and ensure it meets the requirements.
Assembly:
Harnesses are assembled by carefully attaching wires to terminals and connectors, often using automated processes for tasks like cutting, събличане, and crimping.
Testing:
Rigorous testing is performed to ensure the harness’s reliability, издръжливост, and ability to withstand various conditions.
Quality Control:
Manufacturers adhere to quality standards like ISO/TS 16949 to ensure harnesses meet industry requirements.

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Окабеляване на съединител JST UL тел за сглобяване на автомобилни кабелни снопове IATF16949