Automotive Wiring Harness Layout Principles（2）

The wiring harness arrangement involves the body and its accessories, powertrain, chassis, electrical, and many other parts. In the design, these elements need to be considered comprehensively, and potential problems will be avoided in the early stage of the wiring harness arrangement, so as to ensure the various performance qualities of the wiring harness later design, manufacturing, and assembly.

Aesthetics

1. The wiring harness should be arranged in a natural way, and the direction should not be far-fetched. The cabin wiring harness can be placed below the beam, not above it; it can be placed on the inside, not on the outside.

2. The wire harness should be consistent with the direction of the dependent parts, in the projection direction, according to the horizontal and vertical checkerboard arrangement, the wire harness to avoid diagonal layout.

3. Wire harness arrangement should be color coordinated and evenly sized, the cabin wire harness is recommended to use dark plug, and if the wire harness above the engine is too messy, it is recommended to develop an overall wire harness guard.

Avoid high-temperature zone and pipeline

1. Avoid harness arrangement too close to the high-temperature area, if it cannot be avoided, then a heat shield should be added to protect the harness (at least above 80 mm), for a harness without a heat shield, the spacing should be at least above 160 mm, such as exhaust system, EGR and boost system and its related valves and other high-temperature parts. However, the harness is at least 200 mm from the high-temperature area of the exhaust muffler and at least 30 mm from the exhaust manifold.

2. Do not use the same fixing point with the fuel line and brake line, and do not cross or contact with the fuel line and brake line.

3. The arrangement of wiring harness also needs to consider other pipelines around, such as water pipe, vacuum pipe, etc., and do not have contact interference with these pipelines.

Consider anti-electromagnetic interference

1. Avoid parts electromagnetic interference sources, some signal lines will be located as far as possible from the source of interference, electric speakers, motor-type appliances, and other locations.

2. Sensor signal power lines should avoid the power lines of high-current components, the interval should be greater than 300mm, reasonable arrangement of appliances, shorten the length of the signal line.

3. Some key systems, important systems of the lap line are separately arranged in a location to avoid interference from other lap lines.

Consider the harness arrangement of the hole

1. Consider the location and structure shape of the hole at the beginning of the design, and also consider the relative position of the location and other parts.

2. If the wire harness passes through the sheet metal hole from inside the cab to outside, the external wire harness must be lower than the over the hole to avoid the liquid on the wire harness from entering the interior.

3. When connecting the harness of four doors and the harness of the cockpit, the over-wire holes on the doors should be lower than the over-wire holes on the body side surrounding.

4. The reliability of the rubber parts on the wiring harness must be ensured. Wire harness over-hole rubber sleeve must be installed reliably, under normal use, the rubber sleeve can not be out of the installation position.

Other principles

1. Avoid vertical arrangement of the plug as far as possible, to dust and water. The plug does not arrange in the main gathering area or outside the car, must be arranged in the above-mentioned areas to use protective measures. The use of rubber plugs or rubber sleeves, adding petroleum jelly in the plug-in, and other methods to avoid the plug-in water into the terminal surface oxidation.

2. Consider its safety. In a car collision, the wiring harness can not be squeezed. Wire harness extrusion rupture, internal short circuit will instantly cause a fire, causing secondary injury to the driver and passengers.

3. The wiring harness arrangement should also be combined with the electrical principle, according to the requirements of the electrical principle, reasonable design of the wiring harness towards and out of the wire direction.

4. The wiring harness layout should also be combined with its secondary suppliers, such as a plug, fixed parts, rubber parts, and other manufacturers, through the communication between the two sides, choose the appropriate design scheme.

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