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What is an engine wiring harness?

1. The engine wiring harness is composed of wires, cables, terminals and connectors that control the vehicle’s electrical system. It delivers power and control information to components such as batteries, generators, injectors, fuses, audio systems, blowers, injectors and computers. Main types of automotive wiring harnesses: Main wiring harness – controls instruments, control panels, navigation systems, multimedia and electronic equipment. Together with the front and rear wiring harnesses, it forms part of the chassis wiring harness. Engine Wiring Harness – Manages key functions around the engine including the engine controller, oil controller door, transmission plug housing, air line sensor, pressure sensor and water temperature sensor. Body Wire Harness (or Body Wire Harness or Floor Wire Harness) – Keeps the air conditioning system, rear sonar, navigation, dimmer switches and speakers working properly. Front Harness – Forms part of the chassis harness along with the main and rear harnesses. Control air conditioning fans, cooler fans, power sensors, temperature sensors, pedal sensors, speed limit sensors, oxygen sensors, and more. Battery Harness – Provides primary power to other units. Acts as a bridge between the engine and other vehicle components. Door wiring harness-controls door and window locks, door and window power supplies, and speakers. 2.

Wire harness processing process

1.Offline (blanking) process Definition: The so-called off-line is the process of cutting, stripping and bundling wires of different specifications according to the design drawings and process documents. Process: Prepare materials→Adjust equipment→First article inspection (measure wire length, strip head)→Mass production (100% self-inspection during middle and final inspection)→Arrange wires→Waiting for turnover. Inspection: During the off-line process, process parameters such as wire length, fully stripped and half stripped lengths, and opening length need to be measured. 2.Connection process Definition: The so-called crimping is the process of bringing wires and terminals together Process: Prepare materials → Adjust equipment → Make first article → First article inspection (micrometer measures crimping height and crimping width) → Mass production (100% self-inspection of crimping quality during and after inspection) → Waiting for turnover Inspection: The crimping process requires measurement of process parameters such as whether there is an R angle, whether the visible range of the core wire and insulation is within the tolerance range, whether there is damage to the core wire crimping part and the insulation skin crimping part, and the crimping distortion. 3.Packaging (pre-assembly) process Definition: The so-called pre-assembly is the process of assembling semi-finished products after off-line or crimping together with sheaths, pipes, rubber

New energy vehicle high-voltage wire harness connection technology

High voltage wiring harness connection method 1.Crimp connection Crimp connection is to use tools or equipment to deform the connector joints and press them onto the wires through pressure, so that the terminals of the connector and the wires form a mechanical connection, giving them good mechanical and electrical properties. At present, there are three known connection methods for automobile wiring harnesses, but foreign wiring harness cables and plug-in terminals are basically connected by crimping. This process technology is very mature and stable and suitable for actual mass production. Advantages of crimp connections:  Reliable connection, high production efficiency and adaptable to automated production; The connection process does not require solder and flux, which overcomes the difficulty of cleaning the weldment and the easy oxidation of the welding surface; At the same time, the crimping process has low environmental requirements, is simple to operate, and is not prone to human failure. However, its shortcomings are also obvious. After crimping, there is still incomplete contact of the wires, and the contact resistance increases during long-term operation. Eventually, the joints are prone to heat and the power loss is increased, affecting the safety of the circuit. Among them, the crimping height plays a

Understanding of low-voltage wiring harnesses for new energy vehicles

The low-voltage wiring harness of new energy vehicles refers to a set of wires and cables that connect various low-voltage electronic devices and sensors inside the vehicle. Compared with high-voltage wire harnesses, low-voltage wire harnesses have lower operating voltages, generally between 12V and 48V. They are used to transmit power, data and control signals, and drive various low-voltage electronic devices inside the vehicle. 1. Constituting an integral part of the low-voltage wiring harness Battery management system (BMS) wiring harness Used to connect the battery pack and battery management system to monitor battery status, temperature, voltage and other information. Power battery cooling system wiring harness Used to connect the battery pack and the cooling system, transmitting information in the coolant pipeline to maintain the battery temperature within a safe range. Motor controller wiring harness Connect the motor and its controller to transmit the electrical signals and control commands required for motor operation. Charging system wiring harness Used to connect charging sockets, charge controllers and battery packs, and transmit electrical signals and data information required for charging. Vehicle electronic control unit (ECU) wiring harness Connect various electronic modules and sensors of the vehicle to transmit vehicle operating status and control instructions. Car

Photovoltaic cable

Photovoltaic cable is a special cable designed for solar power generation systems. Photovoltaic cable is also called solar cable. Its structural shape is generally single-core circular or double-core parallel lines. It is a cable that uses sunlight as its energy source and uses the photovoltaic effect to convert sunlight into electrical energy. The energized part uses solar panels for photoelectric conversion, converting solar energy into direct current, which is then transmitted through photovoltaic cables and finally output to the load end. Therefore, photovoltaic cables can not only transmit electricity, but also generate it themselves. Photovoltaic cable structure: Photovoltaic cables are mainly composed of solar panels, conductors, insulation layers and sheaths. Photovoltaic cable characteristics: It has the characteristics of weather resistance, high temperature resistance, friction resistance, etc. It has an ultra-long service life. The high-quality oxygen-free tinned copper conductor ensures superior conductive effect. The high-performance insulation material and sheath material cross-linked by high-energy electron accelerator radiation provide reliable insulation and mechanical properties. Photovoltaic cable characteristics Photovoltaic cables have the following characteristics: – Resistant to ozone, UV rays, water vapor – Lead-free, halogen-free, flame retardant, very low smoke emission – Oil resistant – Resistant to chemical corrosion – Temporary overload of conductors

[Cable Knowledge] Types and Selection of Marine Cables

Marine cables, also known as marine cables, are wires and cables for power, lighting, and general control of various ships in rivers and seas and offshore oil platforms and other water structures. According to different uses, marine cables can be classified as follows Cables for lighting and power circuits; Cables for control and communication circuits;  Cables for telephone circuits; Cables for distribution boards; Cables for mobile equipment;  Cables for wiring inside control equipment; Cables for other special devices; Selection principles for ship power cables Select the appropriate cable form according to the cable’s purpose, laying location and working conditions. Select the appropriate cable cross-section according to the working system of the electrical equipment, cable core and load current. Whether the short-circuit capacity of the fragmented cable meets the requirements is based on the calculation results of the system short-circuit current. Then judge whether the allowable current of the cable is greater than the load current, and correct the rated current carrying capacity of the cable according to the ambient temperature. Correct the rated current carrying capacity of the cable, and then determine whether the allowable current of the cable is greater than the load current, based on the correction coefficient

What is a railway wiring harness?

The application of wire harnesses has now been extended to railway construction. Rail transport is one of the most efficient and user-friendly modes of transportation. Every year, experts and professionals in transportation systems seek new technological advancements to improve the operation of rail transportation and its high energy consumption. Before these innovative ideas and expert research, trains consumed a large amount of energy during operation due to the number of electronic systems within the train. Therefore, the designers and manufacturers of these trains are designing new efficient systems to reduce the energy consumed to operate under safe conditions. In other words, the performance of the train depends indirectly on how well the wiring harness is developed. Wiring harnesses are also used in the construction of connecting trains, these types of trains are among the most important in the rail transit industry. The wiring harnesses used in the production of these trains are mostly strong due to their purpose and purpose of connecting the trains. Most connecting trains are used to transport large numbers of people and heavy loads, and they are known to provide comfort and safety to passengers. There are different trains in rail transportation that require wiring harnesses,

Energy storage harness function

The energy storage harness is an important component in the battery pack. Its main function is to connect the individual battery cells in the battery pack to realize the charging and discharging functions of the battery pack. Energy storage harnesses usually consist of wires, connectors, protection devices, etc. In new energy vehicles, energy storage wiring harness plays a vital role. It not only ensures the safe operation of the battery pack, but also improves the performance and reliability of the entire vehicle. Specifically, the energy storage harness can achieve the following functions: Connect the battery cells: The energy storage harness connects the battery cells through wires to form a complete battery pack. In this way, the charging and discharging functions of the battery pack can be realized to meet the power needs of the vehicle. Transmit current: The energy storage harness can transmit the current in the battery pack, thereby realizing the charge and discharge control of the battery pack. At the same time, it can also protect the battery cells by limiting the size of the current to avoid damage to the battery due to overcharge or overdischarge.  Provide safety guarantee: The energy storage wire harness also contains protection

Various cables in audio and video systems

In a professional audio system, people’s attention is usually focused on the main equipment. However, there are many kinds of wires in the audio system. Let’s take you to understand the various wires.   Professional audio cable: Nowadays, Audio wiring harness have two cores, three cores, four cores, five cores, etc. This kind of cable can be used to transmit high-quality audio signals due to its good shielding effect; now more professional microphones generally use three cores. The above wires have strong anti-interference ability and can be used for long-distance transmission. Of course, this kind of wire can also transmit other signals, such as DMX512 control signals for computer lights. Coaxial cable: Generally used in video, there are also some audio cables. Since this cable has poor anti-interference ability and is not designed mainly to transmit audio signals, it is not suitable for long distances. Audio signal transmission.  Centralized cables: Multiple signal lines are wrapped in the same protective tube. They are generally used inside the connection system to reduce the number of independent wires. Now it is also used in TV broadcast trucks, underground pre-burials and other special applications. This kind of thread is generally processed by professional manufacturers,

Cables and Wire Harnesses in the Medical Field

Medical wiring harness—for diverse design needs In the research and development and small batch production of medical equipment, connecting cables in the visible area is a special challenge, which needs to meet multiple requirements such as the number of core wires, outer diameter, outer sheath color and sliding performance at the same time. However, demand for such small quantities often comes with high minimum order quantities. Additionally, off-the-shelf cables are often difficult to color match for specially designed equipment. Orders with a small number of tolerance meters or stocking often lead to a large amount of unnecessary inventory. Therefore, SAB offers its customers unique support: Can be reduced to 100m minimum order quantity. SAB has its own materials department, and the materials we independently produce and develop can meet the various special needs of different customers. Biocompatibility meets EN ISO 10993-1 standards (cytotoxicity meets EN ISO 10993-5 standards) and corresponding certificates can be provided. The color of the outer sheath can be adapted to the device to provide users with a coordinated visual look. Ultra-flexible, non-slip, anti-kink, and sufficient torsion resistance for handheld medical cables. If customers have special needs, we can provide wire harness processing services (see details below).