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​Cause analysis of fatigue fracture of Automotive wiring harness

Views: 0     Author: Site Editor     Publish Time: 2022-01-25      Origin: Site

Under the action of alternating stress, the metal conductor of the Automotive wiring harness has never exceeded the material strength limit. After a long period of repeated stress cycles, the conductor suddenly undergoes brittle fracture. This is the fatigue fracture of the Automotive wiring harness. Next, let us understand the cause analysis of the fatigue fracture of the Automotive wiring harness. Here are some answers.


Here is the content list:

Subject to abnormal mechanical impact.

The cable bending resistance and the layout structure of the Automotive wiring harness cannot meet the needs of actual working conditions.


Subject to abnormal mechanical impact.

Such as impact or mechanical shock, the Automotive wiring harness is short to bear the tension, the brake alarm Automotive wiring harness is too short, the direction will be particularly straight, the Automotive wiring harness will be broken from the inside after a long time, but no problem can be seen on the outside.

Automotive wiring harness

The cable bending resistance and the layout structure of the Automotive wiring harness cannot meet the needs of actual working conditions.

The bending resistance of the cable is related to the single wire diameter of the conductor, the stranded structure of the conductor, and the structure of the cable. The diameter of the conductor monofilament of the high-voltage wiring harness of the new energy vehicle currently in use is selected according to QC/T 1037, the general monofilament diameter is 0.21mm, if you want to change the bending performance of the existing conductor, you can choose a smaller monofilament diameter, such as 0.15mm. Under normal circumstances, the pitch diameter ratio of a bundle of stranded wires should not exceed 25. If it is a multiple-stranded wire, the stranded pitch diameter ratio should not exceed 30. The stranded pitch diameter ratio of the inner and outer layers should not exceed 2O and 14, respectively. Copper wires with large pitches are much harder than copper wires with small pitches, and their allowable minimum bending radius will increase. To prolong the service life of the cable with vibration or moving parts, the flexibility of the conductor must be improved as much as possible, and the thinner the single wire that composes the conductor, the higher the flexibility of the conductor. However, the thickness of a single wire is directly related to its mechanical strength and load-bearing capacity. The thinner the single wire, the worse the load-bearing capacity. To solve this contradiction, multiple single Automotive wiring harnesses can be twisted into strands first. All strands are twisted in the same direction. Then multiple strands are twisted into conductors, and the strands of adjacent layers are twisted in opposite directions during twisting to ensure the flexibility and mechanical strength of the twisted conductors.


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