15 pin 0001530022 964589-1 Automobile waterproof connector ECU Modulo Wire harness plug For Mercedes Benz

5) Electrical safety protection

For wire harnesses, safety is the first priority. The safety protection in wire harness layout design mainly includes the following points:

The positive terminal (battery positive pole, starter positive pole) must be equipped with an insulating plastic protective cover or other protective measures that are not easily deformed, and at the same time ensure that the protective measures are not easy to detach.

The wiring harness cannot use the same fixed point as the oil pipe and brake management, and cannot pass through or be arranged at a cross.

There must be a gap of not less than 20mm between the positive terminal of the battery and the battery cover or engine cover to avoid short circuit, which may cause the battery to explode due to instantaneous high current discharge.

When considering a car collision, the wiring harness cannot be squeezed. If the wiring harness is squeezed and ruptured, an internal short circuit may cause a fire in an instant, causing further harm to the driver and passengers.

During design, the wire harness branches must have sufficient slack (25mm greater than the minimum length of the wire harness) so that they do not produce prestress on the connected electrical components. If the wire harness is too tight, it is easy to cause the position of the fixed point of the wire harness to be misplaced, resulting in an instantaneous increase in the distance between the two fixed points, thereby elongating the wire harness, causing the internal contacts of the wire harness to pull out/virtual connection, the wire parameters to change, and even the wire to be broken.

4 Cost considerations for lightweight design and wiring harness layout

On the basis of satisfying the ease of assembly, maintainability and design reliability of the wire harness, special attention needs to be paid to the lightweight design of the wire harness layout and the cost of the wire harness. There are several aspects to consider:

1) The electrical circuit should be shortened as much as possible

The electrical wiring harness loop must be shortened as much as possible. Short loops can not only reduce weight, but also reduce costs. Short loops can also reduce power consumption in line sections.

For large wire diameters, shortening the loop brings great improvements, such as battery positive cables.

2) Reduce wire harness segments as much as possible.

In actual three-dimensional wire harness design, increasing wire harness segmentation requires adding butt connectors between wire harnesses, and adding butt connectors will inevitably increase the weight and cost of the wire harness. At the same time, it will also increase the voltage drop on the line, which is not conducive to the stability of electrical performance.

Some German cars can see a large line running through the engine compartment, passenger compartment, and luggage compartment. This is a typical design with few segments.

3) Don’t over-design

Avoid using unnecessary wire harness fixing points. In some areas, the wire harness fixing point area can reach 300. At this time, it makes no sense to do 150. Not only does it increase the weight and cost of the wire harness, it is also a waste for the assembly workshop.

4) Reduce the use of buckles of different specifications and reduce the use of new materials

Wire harness fixing parts, such as buckles, cable ties, and rubber parts, can be borrowed if they can, and try to avoid the production of new materials.

At the same time, reduce the types of cable ties/buckles as much as possible. On the same wire harness, avoid the appearance of 7mm round hole cable ties and 7x12 waist-shaped hole cable ties. These are very detrimental to the wiring harness. generation processing.

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