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4.2.3 Optimization of wire types

At present, there are generally four types of wires used in wire harnesses according to customer standards, namely Japanese wires that comply with JASO standards, German wires that comply with VW or DIN standards, wires that comply with ISO 6722 international standards, and wires that comply with national standard GB/T 25085. Among them, Japanese and German wires are the most commonly used. By calculating the current carrying capacity and adding some specifications or supplementing different specifications of wires that meet other standards while meeting the requirements of usage functions, the cost of wire harness components can be reduced while also contributing to the overall weight reduction of the vehicle.

Table 1 takes the German standard FLR type wire as an example (wire specifications are in mm2), and the wire specifications within the marked interval have a larger span. If some specifications are added between the span of the above specifications or Japanese standard wires are used, it can effectively supplement the range of wire specifications, as shown in Table 2.

1) From the feedback of claims and fault information from the after-sales market over the years, it can be seen that wire harness product claims and faults often occur in the engine compartment where the working environment is relatively harsh, while the number of claims for wire harness products in the cab is relatively small. The use of the optimized main wiring harness is not conducive to the maintenance and replacement of the circuit. After dividing the main wiring harness into three parts: engine compartment wiring harness, instrument panel wiring harness, and body wiring harness, it can greatly reduce the labor hours used for after-sales maintenance and the repair costs of the end user.

2) By implementing the "pre assembly of components" plan, while reducing the production and assembly time of wire harness suppliers, it can also improve the loading efficiency of the entire vehicle factory on the final assembly production line.

3) After the main wire harness is split, the variety of wire harness products is diverse, improving the production organization flexibility, logistics management efficiency, and parts delivery rate of the entire vehicle factory.

4) After splitting the main wire harness, the turnover and transportation of finished and semi-finished products of the wire harness can reduce the risk of scratching and dragging caused by long wires. At the same time, it also faces the following challenges: ① After the main wire harness is split, the number of connection points between the wire harnesses increases, increasing the risk points of wire harness product quality; ② After the main wire harness is split, it will increase the number of connectors between the wire harnesses, resulting in an increase in the material cost of the wire harness product.

The optimization of the wiring harness structure ultimately depends on the collaborative cost between the entire vehicle factory and the wiring harness supplier.

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