What are the specific requirements for the performance of low-voltage wiring harnesses?
Publish Time: 2024-08-22
The performance requirements of low-voltage wiring harnesses usually include the following aspects:
Electrical performance:
Conductivity: The wires and terminals should have low resistance to reduce power loss and ensure the normal operation of the electrical system. For example, high-quality conductive materials such as copper with low resistivity are used to make wires.
Insulation: Good insulation performance can effectively prevent current leakage and short-circuit faults. The insulating material should be able to withstand a certain voltage without breakdown and maintain stable insulation performance during long-term use. For example, insulating materials such as rubber and plastic that meet the standards are used to wrap the wires.
Mechanical properties:
Abrasion resistance: During the operation of the vehicle, the wiring harness may rub against other components, so it is necessary to have a certain wear resistance to prevent the outer skin from being damaged and exposing the internal wires.
Bending resistance: It can adapt to frequent bending during vehicle driving. For example, the wiring harness at the connection between the door and the body must ensure that it can still work normally after repeated bending, and the wire will not break or the internal structure will be damaged.
Mechanical strength: The terminals and wiring harnesses should have sufficient mechanical strength to withstand the vibration and impact during the operation of the car, and prevent problems such as loosening, falling off, and wiring harness breakage. For example, at the crimping point between the terminal and the wire, it is necessary to ensure that the connection is firm and can withstand a certain amount of tension and impact.
Environmental adaptability:
High temperature resistance: The temperature in the engine compartment and other parts of the car is high, and the wiring harness needs to be able to work normally in a high temperature environment, and will not cause problems such as reduced insulation performance and softening of the outer skin due to the increase in temperature. It is generally required to withstand temperatures of 125°C or even higher, and the wiring harness in parts such as the engine wiring harness needs to meet this requirement.
Low temperature resistance: In cold climate conditions, the material of the wiring harness cannot become brittle, and still maintain good flexibility and mechanical properties to ensure normal use in a low temperature environment, such as vehicle wiring harnesses in cold northern regions.
Moisture resistance and waterproofness: Prevent problems such as short circuit or corrosion of wires due to moisture intrusion, especially in humid environments or parts that may be exposed to water, such as vehicle chassis, door wiring harnesses, etc. The protective structure of the wiring harness (such as bellows, sealant, etc.) must be able to effectively block moisture from entering.
Chemical corrosion resistance: It can resist the erosion of various chemical substances that may exist inside the car, such as oil, detergents, brake fluid, etc. Use materials with good corrosion resistance to make the wiring harness outer skin and terminals.
Anti-aging: Long-term exposure to the natural environment, it must withstand the influence of factors such as sunlight and oxidation, without rapid aging, cracking, hardening, etc., to ensure the service life of the wiring harness.
Reliability and durability:
Quality stability: Throughout the service life of the vehicle, the low-voltage wiring harness should be able to maintain stable performance and reduce vehicle electrical system problems caused by wiring harness failure. This requires strict control from material selection, production process to quality inspection and other links.
Service life: Meet the design service life requirements of the car, generally for several years or even longer, during this period of time, there is no need to frequently replace the wiring harness. For example, the wiring harness of a family passenger car is usually guaranteed to work reliably within a service life of more than 10 years.
Other performance:
Electromagnetic compatibility (EMC): In the vehicle, there are various electronic equipment and electrical systems. The wiring harness should have good electromagnetic compatibility, reduce its own electromagnetic interference to other equipment, and at the same time resist the influence of external electromagnetic interference on its transmission signal to ensure the accuracy of signal transmission.
Easy to install and repair: The design and layout of the wiring harness should be easy to install on the vehicle, and in the event of a fault, it should be easy to detect and repair. For example, the wiring harness should be arranged in a reasonable way, and the branch and contact positions should be easy to find and operate.
Size and flexibility: Depending on the internal space and installation location of the vehicle, the wiring harness needs to have the appropriate size and flexibility to adapt to the complex wiring environment, and at the same time, it should not be too large or too hard to be difficult to install or affect the normal operation of other components.
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