How can low voltage wiring harness meet the specific voltage and current transmission requirements through precise design?
Publish Time: 2024-12-11
In modern electrical systems, low voltage wiring harness plays an extremely critical role, and its precise design is the core element to meet the specific voltage and current transmission requirements.
First, the precise selection of wire diameter is the basis. According to Ohm's law, current is inversely proportional to resistance, and wire diameter directly affects the resistance value of the wiring harness. Designers need to accurately calculate the required wire diameter based on the size of the transmitted current. For large current transmission, such as the power supply line of the car starter motor, thicker wires will be used to reduce resistance, reduce power loss in the wiring harness, and prevent safety hazards caused by overheating. On the contrary, for small current signal transmission lines, such as sensor lines, thinner wires are used to ensure stable signal transmission while saving materials and wiring space. Through this precise grasp of the relationship between current size and wire diameter, efficient and safe transmission of different lines at their respective rated currents is ensured.
Secondly, the precise selection of wire materials is crucial. Common wire materials include copper and aluminum. Copper has good conductivity and low resistivity, and is the preferred material for most low voltage wiring harnesses. However, in some application scenarios with strict weight requirements and relatively small current, such as some low-voltage lines in the aerospace field, aluminum wires will be considered, and their conductivity and mechanical properties will be improved through special alloy formulas and processing technologies. When designing, it is necessary to comprehensively consider transmission voltage, current, cost, weight and environmental factors, and accurately determine the most suitable wire material to meet specific voltage and current transmission requirements.
In addition, the insulation layer design also needs to be accurately adapted. The insulation layer must not only provide sufficient electrical insulation performance to prevent short circuits and leakage between lines, but also be able to withstand certain mechanical stress, temperature changes and chemical corrosion. For low voltage wiring harnesses with high voltage difference or working in harsh environments, insulating materials with high insulation strength, wear resistance, high and low temperature resistance and chemical corrosion resistance will be used, and the thickness and uniformity of the insulation layer will be accurately controlled. For example, the insulation layer of the wiring harness in the engine compartment of a car must be able to withstand high temperature, oil pollution and vibration. By accurately designing the material and structure of the insulation layer, it is ensured that the voltage and current are stably transmitted under complex working conditions without being disturbed by external factors.
Finally, accurate planning of line layout and connection methods is indispensable. Reasonable line layout can reduce electromagnetic interference and improve the accuracy of signal transmission. During the design, the direction and branching position of the wiring harness will be accurately planned according to the distribution of electrical equipment and signal flow. At the same time, the type, specification and connection process of the connection terminal must be accurately matched to ensure reliable connection and extremely small contact resistance, thereby ensuring stable and accurate transmission of voltage and current in the entire wiring harness system, so that the entire electrical system can operate normally and efficiently.
