​Design and production of new energy vehicle wiring harness

With the growing popularity of the automotive market, people's requirements for automotive safety, comfort, economy, and emissions are increasing. The application of new energy vehicle wiring harnesses is becoming more and more widespread. And the design of automotive wiring harness systems is becoming more important and stricter.

Here is the content:

Pre-planning

Layout environment

Two-dimensional diagram design

Pre-planning

In the conceptual design and structural design stage of the whole vehicle, we should integrate the awareness of the overall arrangement of the wiring harness and do a good pre-planning. The battery, fuse box, and central control components should preferably be arranged centrally, which not only can save the cost of the main harness, reduce the overall quality of the whole vehicle, improve the aesthetics of the harness arrangement, but also can greatly reduce the risk rate of fire car. According to the function and characteristics of the whole machine to achieve the modularity of the wiring harness system, easy to disassemble and install, easy to repair, save vehicle maintenance and repair time.

Layout environment

The new energy vehicle wiring harness should be arranged to avoid sharp edges, high temperature, oil circuit, water pipe, moving parts area to ensure the reliability of the arrangement. If you cannot avoid it, you need to take appropriate protective measures. The door harness should focus on the consideration of over-hole, sealing, assembly factors, etc., over-hole plastic protection sleeve to prevent the harness due to wear and tear caused by the failure of the function; as far as possible, the arrangement in the dry side of the door to prevent the impact of water leakage on the harness; with a few snaps to fix as many harnesses as possible to reduce the complexity of the opening and assembly in the body.

Two-dimensional diagram design

The wiring harness components are selected from the data parameters of the interface control files of automotive sensors, actuators, central control components, etc., and the automotive circuit schematic, and then combined with the three-dimensional wiring diagram to complete the two-dimensional wiring harness diagram. The 2D wiring harness diagram is mainly oriented to debugging and maintenance, and should contain in detail: the fixing method, fixing position, wrapping method of the wiring harness; local special protection measures; plug connector model and manufacturer; wiring harness part number, wiring harness version; the type, wire diameter, color of each circuit wire, location of the starting and ending end of the circuit; wiring harness technical requirements, etc. It should be ensured that the harnesses has sufficient margin to avoid subjecting the harness to tension or strain. Given that the new energy vehicle wiring harness is a deformed part of the automotive components, its actual length and branch position should be verified by the actual vehicle measurement.

The development of intelligent, lightweight automotive wiring harness has brought unprecedented challenges. From electrical schematic diagrams to two-dimensional wiring harness diagrams, from the design concept to the completion of the new energy vehicle wiring harness design, are justified. The selection and matching of wiring harness-related components should be strictly calculated and calibrated, good design of the wiring harness system, so that wiring harness failure no longer become the culprit of automotive failure.