Automotive Wire Harness Wrapping And Fixing Design

Automotive wiring harnesses are the main body of the network of automotive circuits, and without them, there would be no automotive circuits. As people's requirements for safety, comfort, economy, and emission of automobiles increase, automotive wiring harnesses become more and more complex. However, the space given to the wiring harness in the body is getting smaller and smaller. Therefore, how to improve the comprehensive performance design of automotive wiring harnesses has become the focus of attention.

Wire harness wrap design

The outer wiring harness wrap plays the role of wear-resisting, flame retardant, anti-corrosion, interference prevention, noise reduction, and appearance beautification, generally according to the working environment and space size to develop the following wrap design scheme.

Engine harnesses work in a harsh environment, so they are all wrapped with bellows that are highly flame-retardant, waterproof, and have high mechanical strength.

The front cabin wire working environment is also relatively poor, most of the branches are also wrapped with bellows with good flame retardancy, and some branches are wrapped with PVC pipes.

instrumentation line working space is small, the environment is relatively good, available tape full wrap or flower wrap.

The door line and headliner line workspace is small, available tape full wrap, part of the branches can be wrapped with industrial plastic cloth; finer headliner line can be directly glued to the body with sponge tape.

Chassis line because of more contact parts with the car body, so the bellows wrap to prevent wear and tear of the harness.

Performance analysis of raw materials used for wrapping

1. Bellows

Bellows in the wiring harness wrapping generally account for about 60%, or even more. The main feature is good wear resistance, high-temperature resistance, flame retardancy, heat resistance in the high-temperature zone are very good. The temperature resistance of bellows is between -40-150℃. It is generally divided into PP and PA 2. PA material is better than PP material is flame-retardant and wear-resistant, but PP material is stronger than PA material in bending fatigue resistance.

2. PVC pipe

The function of PVC pipe is similar to the corrugated pipe; PVC pipe has better flexibility and resistance to bending deformation, and PVC pipe is generally closed, so PVC pipe is mainly used in the branch of the wire harness bend, in order to make the wire round and smooth transition; the heat-resistant temperature of PVC pipe is not high, generally below 80℃.

3. Tape

Tape in the harness to play a bundling, wear-resistant, insulation, flame retardant, noise reduction, for marking, etc., in the wrap material generally accounts for about 30%. The tape for the wire harness is generally divided into PVC tape, air velvet tape, and cloth-based tape 3. PVC tape wears resistance, flame retardant better; temperature resistance in 80 ℃, noise reduction is not good, the price is cheaper. The material of fleece tape and cloth-based tape is PET. fleece tape has the best wrapping and noise reduction, and the temperature resistance is around 105℃; cloth-based tape has the best abrasion resistance and the highest temperature resistance is around 150℃. The common disadvantage of fleece tape and cloth-based tape is that it is not flame-retardant and expensive.

Wire harness fixing design

The central electrical box is generally fixed by a steel plate bar, bolt, etc., or directly installed on the body with the fixed structure designed by the electrical box itself.

Each wiring harness is generally fixed in the body hole with plastic ties and snap hooks. Most of the body holes are round or elliptical holes, generally with diameters ranging from 5mm, 6mm, 7mm.

The sheaths of the docking between each harness are generally fixed up collectively with sheath brackets and mounted on the body.

Larger models with long and thick body lines are generally fixed on the body with sheathing to reduce vibration and noise.

Here ends the sharing, and we hope this article was helpful to you! We are an automotive wire harness supplier, please feel free to contact us if you need them!