Whether it is the design of automotive wiring harness products or the process of manufacturing, it is best to consider the error-proof design of the connector from the source and fundamentally solve the problem so that the error-proof position can be identified. Especially for the automotive wiring harness project developed by the whole service, in the early stage of the wiring harness product design, it is necessary to make full use of structural error proofing, component error proofing, color error proofing, size error proofing, docking error proofing and other comprehensive error proofing technologies to ensure the integrity of the automotive wiring harness. Error-proofing in manufacturing and loading, realizing blind installation of automobile wiring harnesses in the OEM without errors and correct loading, realizing correct identification of products during the manufacturing process of automobile wiring harnesses, and correct interpretation of drawings without ambiguity.
● The wiring harness connector connected to the functional end of the automobile electrical appliance shall use the connector with CPA, and the plug-in connection shall be locked twice to avoid accidental failure of the electrical function due to accidental touch or other external causes; Larger electrical terminal wiring harness connectors use connectors with handles to ensure smooth insertion and reliable locking of the connectors, which can effectively avoid the defects of crooked pins and poor connection; In addition to using different colors for the two connectors, limit slots should be added to ensure that they are inserted correctly once.
● The terminal insertion error-proof design of the connector, the terminal jack of the connector should be designed with a limit slot, the terminal can be inserted in the correct direction, and it can be locked after insertion. The hole position terminal specification of the composite connector is significantly different, and the terminal is inserted correctly. The terminal hole and the probing hole of the connector are different, and the terminal is prohibited from passing through the probing hole.
● The color of the mating male and female connectors between the harnesses should be the same, and the mating connector with CPA function is preferred. For connectors with the same outlet from adjacent locations, in addition to color differences, structural differences, and male and female connectors, different branch lengths should be designed for error-proof design or different sheath outlet directions.
● When the material of the door wiring harness is selected, the connector of the door wiring harness and the body wiring harness should preferably be a connector with a latching mechanism to ensure that the door is frequently opened and closed to avoid the phenomenon of butt loosening. The door rubber parts should be embossed and stamped “L or R” to distinguish left and right.
● The error-proof design of the buckle of the automobile wiring harness can effectively prevent the wrong direction or position of the loading wiring. The OEM usually designs the sheet metal holes or card slots of different sizes, different shapes, different directions, and different fixed installation methods on the automobile sheet metal. There are also obvious differences in the specifications of the clips, buckles and cable ties on the wire harness, which can effectively avoid the installation error of the wire harness.
● Some of the branches of the ceiling wiring harness are fixed by tape, and blue tape should be used to mark the sticking position on the wiring harness. The main engine factory should stick and fix the wiring harness and the ceiling object according to the marked position to prevent the wrong sticking and fixing.
● No heavy-colored wires should be designed in the same sheath. If heavy-colored wires cannot be avoided, different wire diameters should be used. The ground terminal of the other end of the common voltage connection can use the wire of the same color and the same wire diameter.
● If the total length of a wire harness is greater than 1.30m, it is forbidden to add optical fibers to the wire harness. The selection of optical fibers and the relevant technical requirements for protection should take into account the various restrictions in the area of use (temperature, aggressiveness, bending radius), whether or not Combined with the instrument panel wiring harness, the optical fiber should comply with the technical requirements of STE 9629787199, the average bending radius of the optical fiber is not less than 25 mm, and some pulse generators should be added if necessary.
In the early stage of product design, automobile wiring harnesses introduce error-proof design, which can completely avoid many errors in the process of wiring harness loading and wiring harness manufacturing. It is also the source of error-proofing wiring harness design. There are many kinds of error proofing applications for automotive wiring harness product design, and we will discuss them together.
