Reliability Analysis of power & Signal Connecting Cables

Reliability is an emerging scientific discipline in recent years, which always runs through all technical fields. The safety of automotive wiring harness design is crucial to the entire automotive electronic system. The reliability of the wiring harness design is a reflection of safety. This article’s wiring harness engineer’s automotive wiring harness reliability analysis content.

Reliability Analysis of power & Signal Connecting Cables

Reliability analysis of line terminals and connectors
As an important part of the automotive wiring harness, line terminals and connectors are the main components that determine the reliability of the wiring harness system and play a vital role in the wiring system. Terminals and connectors account for a large part of the many problems that occur in wiring harnesses. For example, the terminals are aging, and the connector components have fallen off, loosened, and been damaged due to time. These problems may be a small detail in normal times, but if placed in the entire wiring harness safety system, they will lead to a reduction in the safety and reliability of the wiring harness. Therefore, in the usual wire harness design, certain measures must be taken to ensure the reliability of the wire harness design. For example, during the installation process, choose appropriate connectors and plug-ins, etc.; secondly, pay attention to their materials. The operating temperature of terminals and connectors and the maximum allowable current; pay attention to their working environment and temperature. At the same time, it is necessary to avoid some corrosive gases or liquids from affecting the terminals and connectors, thereby destroying the reliability of the entire electronic system.2 Analysis of the reliability of wire harness protection
The working environment of automobile wiring harness is very harsh, often accompanied by corrosive gases and liquids, as well as high temperature, humidity, and collision and friction with other parts. Problems such as damage to the insulator jacket and loose interfaces often occur, resulting in short circuits or open circuits in the wiring harness, affecting the overall electronic system. Therefore, in order to improve the safety of automobile wiring harness design, it is necessary to make a work plan for wiring harness design and effectively wrap and fix the wiring harness. The design of automobile wiring harness should have measures such as moisture-proof, anti-corrosion and anti-high temperature. At the same time, it is necessary to ensure that it has good air-tight materials to protect the joints and connectors. When installing wiring harnesses in other parts of the car body, professional cable ties and wire clips should be used to fix them to reduce the impact of vibration on the car’s wiring harness during driving. At the same time, some connection positions must be protected to avoid friction between the wire control and the wiring harness, which will lead to wear and tear of the insulating coat. When packaging, it is necessary to analyze the different operating environments of different components to characterize their service life and reliability. It is necessary to conduct various comparative tests on materials to select appropriate materials. It is also necessary to conduct experiments on the reliability of wiring harnesses in harsh environments to prevent substandard products from flowing into the next step.3. Reliability analysis of circuit design of wiring harness
The design of automobile wiring harness system is a very complex project, especially the current loop problem of the line. Under certain environmental conditions, the rational design of the circuit is the core of the electrical system. Under normal circumstances, the circuit line system of a car is connected in parallel among different electronic devices. To test its lines, it is necessary to change the connection method of the lines and simulate what may happen under various circumstances to ensure the normal operation of the wiring harness line system.