Wire Harness Technology

Engineering machinery often utilizes complex electrical systems, and wire harness assemblies play a crucial role in organizing and protecting these wiring networks. These assemblies consist of wires, connecteurs, and other components, all bundled together for efficient and reliable performance. They streamline the production process, improve efficiency, and reduce errors in electrical systems, especially in automation and manufacturing.

Designing crimp points for connecting wire harnesses involves selecting appropriate crimp terminals and ensuring proper crimping techniques to create reliable and secure connections. This process includes choosing the right terminal type for the specific wire gauge and application, using a suitable crimping tool, and verifying the quality of the crimp to prevent issues like shorts or weak connections.

Twisted pair cables are preferred, and the twisted characteristics of the two wires are used to offset common-mode signal interference. They are suitable for scenarios with high signal stability requirements such as automotive wheel speed sensors and CAN buses.

To select the right wiring harness connector, consider the current and voltage requirements, the number of circuits, wire gauge, environmental conditions, termination type, and any specific certifications or agency approvals needed. Also, factor in space constraints, engagement force, and desired mating type (male/female).

CAN (Controller Area Network) is a multi-host local network serial communication protocol developed by the German Bosch company in the early 1980s to solve the problem of data exchange between numerous electronic control units (ECUs) in modern automobiles.

The global automotive wiring harness market is substantial and growing, with estimates reaching over USD 59.5 billion by 2030. The cost of an automotive wiring harness is driven by raw material costs, manufacturing expenses, and other factors like development and transportation. Labor costs, especially for manual production, also contribute to the overall expense.

To choose the right cable ties for wiring harnesses, consider the material, length, width, tensile strength, and environmental conditions. For general use, standard nylon ties are a good choice, but for heavier loads or harsh environments, stainless steel or UV-resistant ties are recommended. Measure the bundle diameter to ensure proper fit and select a tie with adequate tensile strength to support the weight and stress of the wiring harness.

It is connected to all functions in the vehicle via power and data. The dimensionally stable, easy-to-install and space-saving wiring harnesses are also optimized with regard to the vehicle type: whether low-cost car or premium brand vehicle – they all have the wiring system in common.

Proper crimping involves selecting the right crimp terminal and crimping tool, stripping the wire insulation, inserting the wire into the terminal, and using the tool to create a secure connection. A ratcheting crimping tool ensures a uniform and stable crimp.

Reliability analysis of power and signal connecting cables involves evaluating their ability to consistently perform their intended function over a specific period and under defined conditions. This analysis is crucial for ensuring stable signal transmission and reliable power supply, impacting various applications like military equipment and power grids.