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“Explanation of electronic wiring harness knowledge that novices can understand at a glance”

The wiring harness provides overall service equipment for a certain load source group, such as trunk lines, switchgear, control systems, etc. This article mainly explains the definition of wire harness, the composition of wire harness, the material of wire harness, and the selection of wire harness material.


  1. I. Definition of wire harness.

It establishes a communication bridge between two or more isolated electronic circuits, allowing current to flow and realizing various functions of various electronic components. It is an indispensable component in various electrical and electronic equipment.


  1. II. The composition of the wiring harness.

Signal harness: Injection molding required.

The components of ordinary wiring harnesses are: wires, terminals and plastic parts.

Components of complex wiring harnesses need to be added: tape, ties, sleeves, jackets, labels, etc.


(Example product see picture below).

custom wiring harness
Wiring harness distinction


III. Harness material.

Take the material requirements of automobile wiring harnesses as an example: its electrical performance, material dissipation, temperature resistance, etc. are all higher than those of general wiring harnesses. Since automobile wiring harness involves personal safety, the requirements for material safety are higher. Be strict. The following 6 points are the requirements for wiring harness materials in automotive wiring harnesses.


  1. Use shielded wires for weak signal sensors.


  1. The wires on the automatic transmission are made of wires that are resistant to hydraulic oil, high temperature, and have good temperature stability.


  1. The wires of the wiring harnesson the trunk lid must remain elastic at low temperatures, so cold elastic wires must be used to ensure their normal operation.


  1. The stranded wires used in the ABSwire harness assembly are resistant to high temperatures of 150-200°C, have a hard outer protective insulation layer, and are wear-resistant, but there are more than 133 core wires.


  1. The wires used in the starter alternator output wire, battery wire and other power wires are special wires that can withstand large currents and have an insulating layer with good heat dissipation and voltage reduction properties.


  1. The ambient temperature around the engine is high and there are many corrosive gases and liquids. Therefore, the wires of the engine wiring harnessmust use wires that are resistant to high temperature, oil, vibration, and friction.


  1. IV. Selection ofwire harness

The quality of the wire harness material directly affects the quality of the wire harness, and the selection of the wire harness material is related to the quality and service life of the wire harness. Therefore, when choosing wiring harness products, be sure not to be cheap. Cheap wire harness products may use inferior wire harness materials.

Wire harness composition
Wire harness composition

So how to distinguish the quality of wiring harness? Once you understand what the harness is made of, you’ll understand. The following 4 points are information for wire harness material selection. Wire harnesses generally consist of wires, insulating sheaths, terminal blocks and wrapping materials. As long as you understand these materials, you can easily identify the quality of the wiring harness.


  1. Selection of wire harness wires: Select the corresponding wires according to different usage environments.


  1. Selection of insulation sheath materials: Commonly used materials for sheath materials (plastic parts) mainly include PA6, PA66, ABS, PBT, pp, etc. Flame retardants or reinforcing materials can be added to plastics according to actual conditions to achieve the purpose of reinforcement or flame retardancy, such as adding glass fiber reinforcement, etc.


  1. Selection of terminalmaterials: The copper used in terminalmaterials (copper parts) is mainly brass and bronze (the hardness of brass is slightly lower than bronze), of which brass accounts for a larger proportion. In addition, different coatings can be selected according to different needs.


  1. Selection of winding materials:Wire harness winding plays the role of wear resistance, flame retardant, anti-corrosion, anti-interference, noise reduction, and beautifying appearance. Generally speaking, packaging materials are selected based on the working environment and space size. Packaging material choices usually include tape, corrugated pipe, PVC pipe, etc.
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