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Automotive wiring harnesses are the mainstay of automotive circuits. At this stage, the form of the harness is generally composed of wires, connectors, harness wrapping materials, and body fixings. The automotive wiring harness must ensure the transmission of electrical signals, as well as the reliability of the connected circuit, supply the specified current value to the electrical and electronic components, prevent electromagnetic interference to the surrounding circuits, and eliminate short circuits of the electrical appliances.
The wiring harness of the automobile is used for wear-resisting, flame-retardant, anti-corrosion, anti-interference, noise reduction, and beautifying the appearance. Generally, the dressing design scheme is formulated according to the working environment and the size of the space.
(1) dressing design
The engine harness has a harsh working environment, so it is wrapped with a bellows with high flame retardancy, water resistance and high mechanical strength;
The working environment of the front cabin is relatively poor. Most of the branches are wrapped with a flame-retardant corrugated pipe, and some branches are wrapped with PVC heat-shrinkable pipe;
The instrument line has a small working space and a relatively good environment. It can be wrapped or wrapped with tape.
The door line and the canopy line have a small working space, which can be fully wrapped with tape, and some branches can be wrapped with a PET winding tube;
The thinner top line can be glued to the body with a sponge tape;
Because the chassis line has more contact parts with the vehicle body, it is wrapped with a bellows to prevent the wire harness from being worn;
The position of the door and the cab is high in vibration and noise reduction, and is wrapped with sponge tape. .
(2) Materials for dressing
Generally use bellows, heat shrinkable tube, PET winding tube, tape, sponge tape, etc.
1. Bellows
The bellows generally accounts for about 60% of the wire bundle wrapping position, and the open bellows is often used. Its main features are good wear resistance and high temperature resistance. The temperature resistance of the bellows is between -40 and 150 °C, and the flame retardancy is excellent. The bellows itself has good flexibility and good bending resistance. Bellows are most common in the engine room as well as in the front and rear guard structures.
The bellows are made of polypropylene (PP), nylon (PA), polypropylene modified (PPMOD), and the like.
PA material is superior to PP material in flame retardant and wear resistance; however, PP material is stronger than PA material in bending fatigue resistance.
2. Heat shrinkable tube
The heat-shrinkable tube has high temperature shrinkage, soft flame retardancy, insulation corrosion resistance, good flexibility and bending resistance, low shrinkage temperature and fast shrinkage. Widely used in various automotive wiring harness positions. Generally closed, the wear resistance is general, and the voltage level is mostly 600V.
The heat-shrinkable tube is mainly used in the four-door and the cab with relatively good environment, especially at the branch of the wire harness to make the wire smoothly transition.
The heat shrinkable tube is divided into a single wall heat shrinkable tube and a double wall heat shrinkable tube (including glue).
The heat shrinkable tube is divided into materials, which can be divided into PVC heat shrinkable tube, crosslinked polyolefin (including PE, PP) heat shrinkable tube, crosslinked PET heat shrinkable tube
2. Heat shrinkable tube
The heat-shrinkable tube has high temperature shrinkage, soft flame retardancy, insulation corrosion resistance, good flexibility and bending resistance, low shrinkage temperature and fast shrinkage. Widely used in various automotive wiring harness positions. Generally closed, the wear resistance is general, and the voltage level is mostly 600V.
The heat-shrinkable tube is mainly used in the four-door and the cab with relatively good environment, especially at the branch of the wire harness to make the wire smoothly transition.
The heat shrinkable tube is divided into a single wall heat shrinkable tube and a double wall heat shrinkable tube (including glue).
The heat shrinkable tube is divided into materials, which can be divided into PVC heat shrinkable tube, crosslinked polyolefin (including PE, PP) heat shrinkable tube, crosslinked PET heat shrinkable tube
3, PET winding tube, PET braided tube
The wound tube has a black mesh protective sheet and is wrapped on the wire bundle after being curled. The main feature is that the softness is good and the bending is convenient. Due to its poor wear resistance, it is generally less common. Where the main harness needs to be bent, or where the thicker cable branch is visible.
The main feature of PET braided tubes is that they are soft and easy to bend, and are less used in automobiles.
4, wire harness tape
Tape winding is the most basic and most commonly used protective material for wire harnesses. All wire harnesses need to be fixed by tape. The tape has good corrosion resistance, oil resistance and insulation properties. The wire bundle functions as a bundle, wear, insulation, flame retardant, noise reduction, marking, and the like.
According to the degree of wire harness protection, the tape wrapping method is divided into full wrapping, partial wrapping, and flower wrapping.
According to the tape substrate, it can be divided into PVC tape, high temperature resistant PVC tape, cloth base tape, flannel tape, sponge tape and the like.
PVC tape
Good wear resistance and flame retardancy; temperature resistance is around 80 °C, noise reduction is not good, and the price is relatively cheap.
High temperature resistant PVC tape
Good wear resistance and flame retardancy; temperature resistance is around 105 °C.
The cloth tape can be further divided into polyester cloth tape, fiber cloth tape, non-woven tape, and flannel tape. The substrate is mostly PET.
Polyester cloth tape
The substrate is a PET polyester cloth base. The temperature resistance is around 150 °C, which can be used for high temperature winding of the wiring harness of automobile engine area.
Fiber cloth tape
The substrate is a cotton fiber cloth or a PET fiber cloth. With high temperature resistance, hand tearing and good flexibility, it is used for high temperature winding of automotive wiring harnesses.
Non-woven tape
The substrate is a PET nonwoven fabric. The temperature resistance is around 125 °C, and it has good noise reduction performance, flexibility, and can be manually torn.
Flannel tape
The substrate is PET flannel or polyamide flannel. Good resistance to high, abrasion, oil and aging resistance, temperature resistance at around 105 °C, outstanding bandaging performance and noise reduction performance.
Sponge tape
Its function and use are similar to tape. The main feature is that the noise reduction and shock absorption performance is good. It is mostly used in the door and the cab where vibration and noise reduction are required, which can eliminate the abnormal noise of the wire harness.
