Automotive Wiring Harness Kit assembly Supplier

The car wiring harness is the main body of the car’s electricity, signal and circuit network connection. Automotive electrical circuits do not exist without wiring harnesses. Wiring harness refers to the copper pierced contact terminal (connector) and the wire and cable after being crimped, and then the plastic insulator or metal casing on the outside. Set of terminal wires that forms a connection circuit by bundling wire harnesses. The wire harness industrial chain includes wire and cable, connectors, processing equipment, wire harness manufacturing and downstream application industries. Wire harnesses are widely used and can be used in automobiles, household appliances, computers and communication equipment, various electronic instruments and meters, etc. The body wiring harness is connected to the entire body, and its general shape is H-shaped.

Introduction of automotive wiring harness
Automotive wires, also known as low-voltage wires, are different from ordinary household wires. Ordinary household wires are copper single-core wires with a certain hardness. The automotive wires are all copper multi-core flexible wires, some of which are as thin as hair, and several or even dozens of soft copper wires are wrapped in plastic insulating tubes (polyvinyl chloride), which are soft and not easy to break.
Due to the particularity of the automotive industry, the manufacturing process of automotive wiring harnesses is also more special than other ordinary wiring harnesses.
There are roughly two types of systems for manufacturing automotive wiring harnesses:
1. Divided by European and American car series, including China:
The TS16949 system is used to control the manufacturing process.

2. Mainly Japanese cars:
Such as Toyota, Honda, they have their own system to control the manufacturing process.
With the increase of automobile functions and the widespread application of electronic control technology, there will be more and more electrical components, more and more wires, and the wiring harness will become thicker and heavier. Therefore, advanced automobiles have introduced the CAN bus configuration and adopted a multiplex transmission system. Compared with the traditional wiring harness, the multi-channel input device greatly reduces the number of wires and connectors, making wiring easier.

Commonly used automotive wires
The common specifications of the wires in the automobile wiring harness are wires with a nominal cross-sectional area of 0.5, 0.75, 1.0, 1.5, 2.0, 2.5, 4.0, 6.0 and other square millimeters. (The nominal cross-sectional areas commonly used in Japanese cars are 0.5, 0.85, 1.25, 2.0, 2.5, 4.0, 6.0, etc. square millimeters). Each of them has a allowable load current value, which is used for wires of different power consumption equipment. Taking the vehicle wiring harness as an example, the 0.5 gauge line is suitable for instrument lights, indicator lights, door lights, dome lights, etc. The 0.75 gauge line is suitable for license plate lights, front and rear small lights, brake lights, etc. The 1.0 specification line is suitable for turn signals, fog lights, etc. The 1.5 gauge line is suitable for headlights, horns, etc. Main power lines such as generator armature wires, ground wires, etc. require 2.5 to 4 square millimeters of wires. This only refers to the general car, the key depends on the maximum current value of the load, such as the ground wire of the battery, the positive power line is a special car wire used alone. Their wire diameters are relatively large, at least more than a dozen square millimeters, and these “big mac” wires will not be woven into the main wiring harness.

Arrangement of automobile wiring harness
Before arranging the wiring harness, draw the wiring harness diagram in advance. A wiring harness diagram is not the same as a circuit schematic diagram. A circuit schematic is an image that expresses the relationship between various electrical parts. It does not reflect how electrical parts are connected to each other, and is not affected by the size and shape of each electrical component and the distance between them. The wiring harness diagram must take into account the size and shape of each electrical component and the distance between them, and also reflect how the electrical components are connected to each other.
After the technicians in the wiring harness factory make the wiring harness board according to the wiring harness diagram, the workers cut and arrange the wires according to the regulations of the wiring board. The main wiring harness of the whole vehicle is generally divided into engine (ignition, EFI, power generation, starting), instrumentation, lighting, air conditioning, auxiliary electrical appliances and other parts, with main wiring harness and branch wiring harness. A vehicle main wiring harness has multiple branch wiring harnesses, just like tree trunks and branches. The main wiring harness of the whole vehicle often takes the instrument panel as the core part and extends forward and backward. Due to the length relationship or the convenience of assembly, the wiring harness of some cars is divided into the front wiring harness (including instrumentation, engine, headlight assembly, air conditioner, battery). Rear wiring harness (tail light assembly, license plate light, trunk light), roof wiring harness (door, dome light, audio horn), etc. Each end of the wire harness will be marked with a number and letter to indicate the connection object of the wire. Operators can see that the logo can be correctly connected to the corresponding wires and electrical devices, which is especially useful when repairing or replacing wiring harnesses. At the same time, the color of the wire is divided into single-color wire and double-color wire, and the use of the color is also regulated, which is generally the standard set by the car factory. my country’s automobile industry standard only stipulates the main color, for example, it stipulates that single black is used exclusively for ground wires, and red single color is used for power lines, which cannot be confused.