Custom Electric Control System Assembly Wiring Harness

Definition wiring harness is the combination of electrical cables, or assembly of wires, that connects all electrical and electronic (E/E) components in the automotive vehicle, like sensors, electronic control units, Batterien, and actuators.

ize the wiring harness electronic control system assembly wiring harness according to your drawings or sample requirements; provide controllers, displays, intelligent distributed IO, operation panels and other electronic products and vehicle electronic control system solutions for mobile machinery and equipment customers.

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OK, I’m now going to deal with the user’s question: “Assembling wiring harnesses in electrical control systems”. First, I need to understand the user’s needs. They may be looking for guidance on how to assemble wiring harnesses in electrical control systems, including steps, process requirements, precautions, usw. Next, I’m going to look at the search results provided to see which information is relevant.

First look at the patent information in the search results. The two patents mention adjustable wiring troughs and wiring harness connection devices, which may be related to the layout and connection of wiring harnesses. But the user’s question is about the process of assembling wiring harnesses, so these patents may be used as technical background references, but may not be the main source of information.

Then look, these web pages all directly discuss the process, process requirements and precautions of wiring harness assembly. Zum Beispiel, the article describes the process of cable assembly in detail, including the processing of wire ties, wiring requirements, usw. ‌Specifically explain the steps of wiring harness assembly, such as sub-material number production, wiring, PIN insertion, wire binding, electrical testing and other processes. ‌The layout principles of engineering machinery wiring harnesses are mentioned. Although it is early, it may be of reference value for the overall direction and fixed points.

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Now you need to sort out this information and synthesize a structured answer. Possible structures include process flow, wiring requirements, quality inspection and other parts. Note that each part should cite different search results to avoid repeated citations of the same source.

It should be noted that the user requires the current date to be April 8, 2025, so pay attention to the time validity of the information. Zum Beispiel, ‌1 and ‌2 in the search results are both patents from 2025, which may be relatively new, but it depends on whether they are directly related to the assembly process. The time of ‌6 is 1977, which may be a bit outdated, but the wiring principles in it may still be applicable, so it needs to be cited with caution.

Zusätzlich, the user emphasized not to use expressions such as “according to the search results”, but to use superscripts to mark the source. daher, the source must be correctly marked at the end of each sentence, and each paragraph must have a reference, and it cannot be concentrated in one paragraph.

Zum Beispiel, when describing the process flow, it can be listed in steps, and the corresponding search results can be cited after each step. Zum Beispiel, sub-material number production reference, wiring step reference, wire binding reference, usw. Gleichzeitig, be careful not to repeat the same source multiple times, and try to cite different source combinations at each point.

The challenge may be how to integrate information from different sources into a coherent process and assign references correctly. It is necessary to ensure that each step has sufficient source support and the reference format is correct. Zusätzlich, it is necessary to exclude irrelevant information. Zum Beispiel, the specific structure in the patent may not directly involve the assembly process and may not be cited.

Finally, check whether there are any missing key points, such as quality inspection, fixed point layout, wiring requirements of the harness, usw., to ensure that all aspects that users may be concerned about are covered. Gleichzeitig, keep the answer structure clear and use lists and segments to improve readability.

Electrical control system assembly harness process and specification requirements

I. Core process of harness production and wiring

‌Sub-material number cutting and quality inspection‌
Sub-material number cutting must strictly refer to the positioning plate size to avoid resource waste due to size deviation‌.

After cutting, electrical testing and full inspection are required to ensure that the wire quality and the tolerances of terminals and connectors meet the requirements‌.

‌Wiring process specifications‌
‌Partition wiring‌: Lay the sub-material number flat on the positioning board according to the requirements of the drawing, follow the order of “single area first, then cross-area”, and complete the cross-area wiring step by step from simple to complex‌.
‌Wiring requirements‌:
Signal lines and power lines need to be tied separately, input/output wires should not be in the same bundle, and shielded wires should be used when necessary‌.
The wiring harness should avoid forming a loop, and the grounding points should be concentrated to reduce electromagnetic interference‌.
Route along the fixed position of the rack, with the projection direction horizontal and vertical, and use an H-type structure to shorten the length of the harness‌.
‌Plug-in and binding operation‌
‌PIN insertion‌: The unplugged terminal needs to be accurately inserted into the corresponding connector to ensure that the core wire is not entangled or too tight‌.
‌Binding process‌:
The spacing between the binding rings is about 25mm, the starting point is at the starting point of the double line, the knot needs to be tied and a 10mm tail is retained‌.
When using a cable tie to fix it, it needs to be tightened, and the tail should not exceed 1mm to avoid wire jamming or loosening‌.

II. Quality Inspection and Control
‌Electrical Testing and Verification‌
Electrical testing is required after assembly is completed. Before testing, the product engineer (PE) and the quality engineer (QE) jointly confirm the accuracy of the test data.
‌Full Inspection Standard‌
Check the position tolerance and wire binding uniformity of the terminals and connectors (CONN).
Check the assembly method of the components and the parallelism of the harness to ensure that there is no movement or friction damage.

III. Engineering Application and Optimization
‌Spatial Adaptability‌: The adjustable wiring trough structure (such as patent CN 222721769 U) is used to adjust the spacing between the splints to adapt to different numbers and sizes of harnesses and improve space utilization. 1.
‌Connection Reliability‌: The circular terminal connection device (such as the patented Shiyan Huiwang solution) is used to achieve stable electrical connection through a plug-in design to simplify the test process.

IV. Process Precautions ‌Fixed Point Arrangement‌: The harness needs to have enough fixed points to avoid displacement due to deadweight or vibration, and the bending radius needs to be controlled at the bend.
Protection requirements: Exposed wiring harnesses must be kept away from sharp edges or moving parts to prevent mechanical damage.

Connectors: Deutsch (Germany), TE (USA), round terminals

Applications: counterbalanced forklifts, electric pallet trucks, electric stackers, aerial work vehicles, tractors, multi-purpose trucks, usw.;
Name: Electric control system assembly wiring harness;
Processing technology: riveting, Schweißen, assembly;
Customization or not: Customize the wire harness length, specifications, Farben, usw. according to customer needs;
Wiring harness exterior: corrugated tube;
Wire: QB electronic wire;
Withstand voltage: DC300V, 10 milliseconds;
Connectors: German Deutsch (Germany), American Tyco (TE), round terminal;
On-resistance: ≤2 ohms;
Wasserdichte Note: IP67;
Isolationsresistenz: ≥5 megaohms;
Plug and unplug cycle: ≥5000 times;
Salt spray test: ≥48 hours

Application areas: sightseeing vehicles, counterbalanced forklifts, electric pallet trucks, electric stackers, aerial work vehicles, tractors, multi-purpose trucks, usw.;

Produktleistung: The manufacturer selects high-quality materials. The product is highly flexible, acid and alkali resistant, oil resistant, moisture-proof, mildew-proof, flame-retardant, abrasion-resistant, corrosion-resistant, antioxidant, wasserdicht, dust-proof, and UV-resistant.

Made of high-quality environmentally friendly TPU material, it has strong insulation performance, wear resistance and corrosion resistance, and long service life; high-quality wire core, high temperature resistance, fire retardant, and the wire body is strong and not easy to break.

Produktzertifizierung: IPC620, IP67, REACH, ROHS2.0, MASDS

Company honors and qualifications: National High-tech Enterprise, UL, IPC620, ISO9001, ISO14000, ISO13485, IATF16949, usw.