1、 Car harness

Automobile wire harness (automobile wire harness) is used to realize the circuit physical connection of the power supply and various electrical parts on the vehicle. The harness is distributed all over the vehicle. If the engine is compared to the heart of the car, then the harness is the neural network system of the car, which is responsible for the information transmission between various electrical parts of the car.

There are roughly two types of systems for manufacturing automobile harnesses

(1) Divided by European and American countries, including China, the TS16949 system is used to control the manufacturing process& nbsp;

(2) Mainly Japan: Toyota and Honda have their own systems to control the manufacturing process.

The automobile harness manufacturer has its particularity, and attaches importance to having cable production experience and cable cost control.

2、 Brief introduction of common materials for automobile wire harness

1. Wire (low-voltage wire, 60-600V)

Type of wire:

National standard line: QVR, QFR, QVVR, QBV, QBVV, etc

Daily marking: AV, AVS, AVSS, AEX, AVX, CAVUS, EB, TW, SHE-G, etc

German markings: FLRY-A, FLRY-B, etc

American standard line: SXL, etc

Common specifications include wires with nominal cross-sectional area of 0.5, 0.75, 1.0, 1.5, 2.0, 2.5, 4.0, 6.0 and other mm2

2. Sheath

Sheath (rubber shell), usually made of plastic, inserts the wire of the pressed terminal into it to ensure the reliability of connection. The materials mainly include PA6, PA66, ABS, PBT, PP, etc;

3. Terminal

A shaped hardware component, which is crimped on the wire to connect different wires to transmit signals, including male terminal, female terminal, ring terminal and round terminal.

The materials are mainly brass and bronze (the hardness of brass is slightly lower than that of bronze), of which brass accounts for a large proportion.

2. Sheath accessories: waterproof plug, blind plug, sealing ring, lock, buckle, etc

Generally used to form connectors with sheath terminals

3. Wire harness through-hole rubber part

It plays the role of wear-resisting, waterproof and sealing. It is mainly distributed at the interface between the engine and the cab, the interface between the front cabin and the cab (2 in total), the interface between the four doors (or the back door) and the compartment, and the inlet of the fuel tank.

4. Tie (clip)

An original is usually made of plastic, which is used to fix the wire harness in the car. There are ties and bellows locking ties.

5. Pipe

It is divided into corrugated pipe, PVC heat-shrinkable pipe and fiberglass pipe. Braided pipe, winding pipe, etc. Used to protect the harness. (Classified by diameter)

① Bellows&nbsp& nbsp;

Corrugated pipes generally account for about 60% or more of the bundle binding. The main feature is good wear resistance, high temperature resistance, flame resistance and heat resistance in high temperature area. The temperature resistance of bellows is between - 40-150 ℃. Its materials are generally divided into PP and PA. PA material is superior to PP material in flame retardance and wear resistance; However, PP material is stronger than PA material in bending fatigue resistance& nbsp;& nbsp;

② PVC heat-shrinkable pipe PVC pipe has the same function as corrugated pipe. The PVC pipe has good flexibility and bending deformation resistance, and the PVC pipe is generally closed, so the PVC pipe is mainly used at the branch of the harness bend to make the wire smooth transition. The heat resistance temperature of PVC pipe is not high, generally below 80 ℃.

6. Tape

Production tape: wrapped on the surface of the harness. (It is divided into PVC, sponge tape, cloth tape, paper tape, etc.). Quality identification tape: used to identify the defects of production products.

Tape plays a role in binding, abrasion resistance, insulation, flame retardance, noise reduction, marking, etc. in the bundle, and generally accounts for about 30% of the binding materials. The tape for wire harness is generally divided into three types: PVC tape, air flannelette tape and cloth base tape. PVC tape has good abrasion resistance and flame resistance; The temperature resistance is about 80 ℃, the noise reduction is not good, and the price is relatively cheap. The material of flannelette tape and cloth base tape is PET. The flannelette tape has the best binding and noise reduction properties, and the temperature resistance is about 105 ℃; The cloth base tape has the best abrasion resistance, and the maximum temperature resistance is about 150 ℃. The common disadvantages of flannelette tape and cloth base tape are poor flame retardance and high price.