What is a wiring harness in a car? Automotive wiring harness manufacturers in china

 

What is a wiring harness in a car?

Car wiring harness is an important electrical component in vehicles, consisting of multiple different parts used to connect and transmit power, signals, and data. Typically, car wiring harnesses consist of the following main components:

1. Wire: The car wiring harness contains multiple wires, which are used to transmit current and signals. They are usually identified by color and number for easy identification during installation and maintenance.

2. Connector: A connector is a component used to connect wires, which has an insertion and locking mechanism to ensure a secure connection of the wires. Connectors are usually located at both ends of the wiring harness to connect to the vehicle's electrical system or equipment.

3. Insulation material: Insulation material is used to wrap wires to ensure that there is no short circuit between wires and to prevent damage to the wires from the external environment. These insulation materials are usually made of plastic or rubber.

4. Leads: Leads are metal wires inside a connector that transmit current or signals from one connection point to another. Leads are usually made of copper or aluminum and have good conductivity.

5. Protective sleeve: A protective sleeve is an external protective layer used to wrap the entire wiring harness. They are usually made of wear-resistant materials to protect the wiring harness from physical damage, moisture, and chemical substances.

6. Branch wiring harness: In automotive wiring harnesses, it may also include branch wiring harnesses used to guide power and signals to different parts of the vehicle, such as headlights, air conditioning systems, engine control units, etc. These branch harnesses are usually connected to the main harness.

7. Electronic module and sensor connection wires: Modern cars contain a large number of electronic modules and sensors, and the wiring harness also includes wires and connectors connecting these modules and sensors.

8. Labels and markings: In order to accurately identify and track different parts of the wiring harness during installation, maintenance, and repair, labels and markings are usually used to indicate the purpose, function, and connection position of each wire.

The design and manufacturing of automotive wiring harnesses is very complex as they need to meet the different electrical system requirements of the vehicle, while also considering the physical structure and environmental conditions of the vehicle. The quality and reliability of wiring harnesses are crucial for the safety and performance of vehicles.

 

 

The Impact of Automotive Wiring Harness Assembly Design on Automotive Safety

Car wiring harnesses play a very important role in the normal operation of cars. It can be said that cars cannot do without wiring harnesses, and all systems and components operate through wire harnesses and cable assembly. Car wiring harnesses can also be divided into the following categories, playing a safe and reliable role in these systems.

 

1. Electrical system safety:

The correct wiring harness design can ensure the stability and reliability of power transmission, prevent short circuits, open circuits, or overheating of wires, and thus reduce the risk of electrical failures.

The correct layout of the wiring harness and the selection of insulation materials can help reduce the occurrence of electrical fires and improve the overall safety of the vehicle.

2. Airbag system:

Airbags are important safety equipment in automobiles, and the design of wire harnesses must ensure the normal operation of airbag sensors and inflation devices. Any wire harness related malfunction may cause the airbag to trigger abnormally or fail to trigger, affecting the safety of passengers in accidents.

3. Braking system and stability control:

The wiring harness contains sensors and wiring related to the braking system and stability control system. If the wiring harness is not designed properly, these systems may not function properly, leading to brake failure or vehicle instability.

4. Lighting system:

Lighting is an important component of night driving, and the wiring harness design must ensure the normal operation of front and rear lights, turn signals, and brake lights to improve vehicle visibility and driving safety.

5. Anti theft and security systems:

The anti-theft system and other security functions typically rely on the vehicle's electronic wiring harness. Poorly designed wiring harnesses may make these systems vulnerable to intrusion or damage.

6. Data transmission and communication:

Modern cars increasingly rely on data transmission and communication technologies, such as in car entertainment systems, navigation, autonomous driving, etc. The wiring harness design needs to ensure the stability and security of data transmission to prevent interference or data leakage.

 

 

How to test car wiring harness?

1. Visual inspection:

• Firstly, conduct a visual inspection to ensure that there is no obvious physical damage to the wiring harness, such as wear, cutting, tearing, or burning.
• Check the connectors and plugs to ensure they are not corroded, loose, or damaged.

2. Electrical measurement:

• Use a digital multimeter or multi-purpose tester to measure the resistance of each wire. Compare the measurement results with the specifications provided by the manufacturer to ensure that the resistance value is within the normal range.
• Measure the voltage and current in the wiring harness to ensure they are under normal operating conditions.
• Use an insulation tester (megohmmeter) to measure the insulation resistance of the wiring harness and ensure that there is no leakage or insulation damage to the wiring harness.

3. Connectivity testing:

• Use a continuity tester to check the continuity in the wiring harness. This can help determine if there are any open or open circuits.
• Test the connectivity of switches, sensors, and actuators to ensure they are correctly connected to the circuit.

4. Electronic diagnostic tools:

• Use vehicle electronic diagnostic tools (such as OBD II scanners) to scan the vehicle's electronic control module to detect fault codes. This can help determine if there are any issues related to the wiring harness.

5. Signal tracking:

• Use signal tracking tools (such as oscilloscopes) to track the propagation path of signals in the wiring harness. This helps identify signal loss, waveform distortion, or interference issues.

6. Jitter test:

• Slightly shake and bend the wiring harness to simulate the vibration of the vehicle while driving. Observe if it can cause any electrical problems, such as sudden disconnection.

7. Temperature test:

• Use a heat gun or heater to conduct temperature tests on the wiring harness to simulate the operation of the vehicle under different temperature conditions. Observe if it will cause any electrical problems.

8. Records and Documents:

• Record the test results and identified issues. This helps to track the maintenance history and problem-solving process of the wiring harness.

 

 

 

The difference between automotive wiring harness standard and ordinary wiring harness.

The main difference between automotive wiring harness standards and ordinary wiring harnesses lies in their design, manufacturing, and use. Here are some key differences between them:

1. Application field:

• Automotive Wiring Harness Standard: This is a wiring harness designed for automotive manufacturing, used to connect various electrical and electronic components in the car, such as the engine, transmission system, dashboard, lighting, air conditioning system, etc. They must comply with strict automotive industry standards and regulations.
• Ordinary wire harness: Ordinary wire harness is usually used for general electrical or electronic applications, such as in fields such as home, industry, electronic equipment, etc. They do not need to meet strict standards in the automotive industry.

2. Quality standards:

• Automotive wiring harness standards: Automotive wiring harnesses must comply with the safety, reliability, and performance standards of the automotive industry. They require strict testing and quality control to ensure stable operation under various extreme conditions.
• Ordinary wire harnesses: The quality standards for ordinary wire harnesses are usually lower because they do not need to meet the requirements of the automotive industry. Their design and manufacturing can vary depending on the specific application requirements.

3. Materials and Protection:

• Automotive wiring harness standards: Automotive wiring harnesses typically use high-quality materials, such as oil resistant, high-temperature resistant, and UV resistant insulation materials, as well as additional protective layers, such as sheaths and insulating sleeves, to improve the durability and safety of the wiring harness.
• Ordinary wire harness: Ordinary wire harnesses may use relatively simple insulation materials and protective measures, depending on the specific application.

4. Connector and identification:

• Automotive wiring harness standards: Automotive wiring harnesses are usually equipped with specialized automotive grade connectors to ensure reliable connections. In addition, they usually have strict markings for easy identification during maintenance and repair.
• Ordinary wire harness: The connectors and markings of ordinary wire harnesses can vary depending on the specific application needs.

5. Electromagnetic compatibility (EMC):

• Automotive wiring harness standards: Due to the presence of many sensitive electronic devices in cars, automotive wiring harnesses typically need to consider electromagnetic compatibility to reduce interference and electromagnetic radiation.
• Ordinary wiring harness: Ordinary wiring harness may not require strict EMC design.

 

In summary, the main difference between automotive wiring harness standards and ordinary wiring harnesses lies in their design, manufacturing, quality standards, and application fields. Automotive wiring harnesses must meet strict automotive industry requirements to ensure the reliability, safety, and performance of the vehicle. Ordinary wiring harnesses are more tailored to the needs of general electrical or electronic applications.

 

YCABLE ELECTRONICS, one of the biggest custom automotive wiring harness manufacturers in China, has advanced production equipment, testing instruments, and a comprehensive quality management system; The company has passed UL, IATF16949, ISO9001, ISO14001 international standard certifications and has been recognized as a national high-tech enterprise; The company has a professional R&D and technical team that can participate in product design, research and development, customization, and provide professional support for new projects for customers.

The company has experience in collaborating with multiple Fortune 500 companies and large domestic enterprises, as well as the ability to deeply integrate electronic component supply chain resources; To provide customized, low-cost, high-efficiency, and high-quality products and services for our customers.

YCABLE ELECTRONICS adheres to the spirit of "honesty based, win-win cooperation" and warmly welcomes customers to negotiate cooperation, mutual benefit and common development!