The application of lightweight in the design of automotive wiring harnesses

In cars, wiring harnesses play an irreplaceable and important role. When comparing the components and microcomputers inside the car to various organs in the human body, wiring harnesses can be compared to blood vessels. Obviously, without blood vessels in the human body, organs are useless. Therefore, it can be seen that automotive wiring harnesses are very important for cars. So, in this discussion, we will focus on the trend and selection of types for the development of automotive end wires, and provide prospects for the future development of automobiles in China.

The weight composition structure of 01 wire harness

Entering the 21st century, China’s economy has developed rapidly, driving a leap in science and technology. The demand for automobiles is also constantly increasing, which has led to an increasing emphasis on the electronic and electrical functions of automobiles. The increase in automotive electronic and electrical equipment has made the wiring arrangement disorderly and exacerbated the number of wires, resulting in vehicle weight gain, reduced fuel economy, and crowded car spaces. In order to change some phenomena, the weight composition structure of wire harnesses has attracted much

(1) Traditional automotive wires generally use vinyl chloride and polyethylene coated wires with good insulation and heat resistance, which are no longer suitable for market demand. In the design of automotive wiring harnesses, wires need to be re selected. Emerging wires are modified to address various inconveniences that arise when using traditional wires. Emerging aluminum wires, ultra-fine wires, alloy wires, and hybrid core wires are more popular in the market, effectively reducing the weight burden of traditional wires on the vehicle body.

(2) According to the different functions of car wiring harnesses, wires with different functions have different performance. For example, the process of identifying the constantly changing external objects in a car is due to its various functional wires, each of which plays its own role and adheres to its own job position, making every part of the car operate efficiently and the various functions of the car run stably. The cross-sectional area of the power line is 2, 3, and 5mm2. It can be seen that wires with different functions have different sizes and cross-sectional areas. In fact, to effectively reduce the weight of wire harnesses, it is necessary to classify and study the different performance of different wire

(3) Car wiring harnesses are the main body of car circuits, and today’s small cars cannot do without these car wiring harnesses. These wiring harnesses are crisscrossed, providing reliable safety protection for cars. Even if they are connected end-to-end, the total length of these wiring harnesses is about 2000 meters. According to the weight of traditional copper alloy wires in cars, the weight of all wires in a car is approximately 25 to 30 kilograms. As the most important part of a wiring harness, the lightweighting of wires is an issue that cannot be ignored.

02 production harness wire

In recent years, automobile lightweighting has been highly valued and gradually become a focus of research. One of the essential parts of a car is the wiring harness, which accounts for approximately 5% of the weight. The reason why cars can run steadily on the road is largely due to the presence of wires inside the car. These wires are irreplaceable objects and constitute the life and internal soul of a car. Therefore, in the process of producing a car, it is necessary to ensure the safety performance of the wires. If low-quality car wires without safety guarantees are selected, once such cars are purchased by users, the consequences will be unimaginable. Cars are not only convenient for people’s lives, but also ensure the safety of drivers and passengers. Only life is the most important thing. Companies should not be greedy for immediate benefits and forget the fundamental concept of business. Life is truly precious. So, it is necessary to choose qualified wires that have been reviewed and approved by professional scientific and technical personnel in order to reliably ensure the safety of users.

Lightweight wiring harness protection. There are many forms of wire harness protection, including protective plates, rubber parts, and brackets. In order to reduce the need for lightweight work, wire harnesses can be protected by reducing the structure of metal brackets and using high-strength plastic protective plates instead of metal brackets. For example, fuse box brackets and engine compartment temperature brackets can be selected based on temperature; Reduce the selection of plastic protective panels by using body structure, special karts, and fixed replacement protective panels; Replacing corrugated pipes with wear-resistant fibers and cloth based fiber pipes can reduce the use of corrugated pipes, while also achieving cost reduction and noise reduction; Choose to replace rubber pipes with foam in areas with low sealing requirements to reduce the use of rubber pipes; In the layout of wire harnesses, minimize internal links as much as possible, which can not only reduce the weight of connectors, but also reduce the auxiliary weight required for connector fixation and the structural weight of the vehicle itself.

It is best for the company to establish a professional technical team, formulate a series of relevant regulations and systems, and strictly treat the selection of wires. It is necessary to actively take it seriously. Because this already involves the safety of users, companies cannot buy low-priced, inferior, and unsafe wires just for the sake of immediate benefits, in order to save expensive costs. This goes against the original intention of cars to benefit humanity and is also a manifestation of irresponsibility towards users. In today’s fiercely competitive automotive market, the most stable thing is quality assurance. Therefore, we must abandon the concept of low cost and aim to provide better driving and riding experiences for purchasing users. Even if the cost is high, it means that the starting point has already surpassed the footsteps of other car stores, which will make it easier to receive the favor of users, attract more repeat customers, and occupy a favorable leading position in the fiercely competitive automotive market, benefiting the company and users. At the same time, this also proves the continuous development and progress of science and technology in our country. This is another major innovation measure in the automotive field, which represents the continuous research and experimentation of scientific and technological personnel in our country. This lays a solid foundation for the future development of science and technology in our country, enabling our country to continuously cultivate various outstanding talents for the takeoff of science and technology. College students continuously input into the field of scientific innovation, ensuring the talent needs of the country. It is also a blessing for the automotive industry. When installing automotive wires, it is important to ensure the quality and safety performance of the wires.

Lightweight considerations for wiring harness layout

When arranging wiring harnesses inside a car, the concept of lightweight should be followed. During assembly, the internal requirements of the car are different, so the type of wiring harness will also be chosen differently. Different wiring harness arrangements may produce different internal structures of the car, leading to different user experiences. Therefore, relevant scientific and technical personnel must develop strict and effective plans to plan how to install wiring harnesses inside the car to minimize the weight of the body. Years of scientific practice have shown that using integrated wiring harnesses inside the car will have greater advantages in reducing the weight of the body. Integrated wiring harnesses often use single section front wiring harnesses and chassis wiring harnesses. The roof wiring harness is combined together, and the middle part saves the connection between the front wiring harness and chassis wiring harness. This first saves resources and avoids unnecessary waste for the Earth, which is an environmental measure. Secondly, it effectively saves the overall weight of the car, enhances the user’s driving or riding experience, and achieves two goals with one stone. The lightweight consideration of wiring harness layout will be favored by users.

The function of a wire harness is to connect the power supply with the electrical appliances, the grounding with the electrical appliances, and the signal communication between various electrical appliances. As is well known, the shortest distance between two points is a straight line. However, due to the consideration of the aesthetics and reliability of the wiring harness layout, as well as the limitations of the surrounding environment, it is impossible to connect wires between each circuit of the wiring harness, and even in all circuits, wires cannot be connected in a straight line. Lightweight wiring harness refers to reducing the number of wiring harnesses, which can achieve the lightest effect on the vehicle body, which is what we call the most reasonable wiring harness

(1) The following are three different wiring harness layout methods, all based on the concept of lightweight layout. From the pictures, it can be seen which method is the most lightweight.

The impact of engine compartment wiring harness layout on lightweight. The wiring harness layout in the engine compartment is also divided into several types, namely H-type layout, C-type layout, and F-type layout. Generally speaking, these three layout methods each have their own reasons and advantages, and each one will be explored within different vehicle models. These three methods have been rigorously developed and tested, and each has its own advantages. The H-type and C-type wiring harness layouts are relatively niche, which can be reflected in other countries. The F-type layout method is widely used in China, although popular, its wiring harness weight can only be considered moderate.

(2) Relevant scientific and technical personnel can start by connecting the internal power supply of the vehicle body to develop various lightweight wire harness schemes. Through repeated comparative experiments, they can choose the scheme that reduces the weight of the vehicle body to the greatest extent. For example, the layout of common fuse boxes and grounding points is taken as an example. If the fuse box and battery are arranged on the same side and the distance is minimized, the power supply wire of the fuse box should be minimized; After distinguishing between power and signal grounding points, the grounding of electrical appliances should be arranged according to the principle of proximity to minimize the length of the wires. The cockpit will adopt various wiring harness

However, each arrangement method will have a certain impact on the wiring harness. We can see the approximate shape of the wiring harness layout through the letters of its layout form, and the wiring harness is arranged on the vehicle floor. The weight of these wiring harness connectors and fixing brackets on the vehicle floor is also relatively objective for the wiring harness. Among all the deployment forms, the H-shaped layout is the best one for wiring harness layout. Because its wiring harness arrangement takes into account the entire range of vehicle electrical appliances involved.


Post time: Mar-12-2024