Automobile wire harness is an important part of electronic and electrical equipment such as automobile power supply, actuator and sensor, and it is also regarded as the “nervous system” of automobile.

If there is no car wire harness, the car circuit will also disappear, resulting in all the electrical functions of the car can not be realized.

At present, the automobile presents the development trend of electrification, intelligence and network connection, which greatly promotes the development of the automobile wire harness, and the requirement of the automobile wire harness is higher and higher.

In recent years, with the vigorous development of new energy vehicles, they are more dependent on the automobile wiring harness, so it puts forward more stringent requirements for the layout of the automobile wiring harness.

1. Function and composition of wire harness for new energy vehicles

The automobile wire harness is the main body of the automobile electrical structure, which runs through all the electrical parts of the automobile. Its main function is to transmit and exchange the input and output signals of the electrical functions of the automobile, and to transfer the current emitted by the battery, motor and other power generation parts to the actuators, so as to realize the cooperative control and management of the automotive electrical components.

The wire harness of new energy vehicle is mainly composed of high voltage wire harness and low voltage wire harness.

The function of the low-voltage wire harness of the new energy vehicle is similar to that of the traditional vehicle, which is mainly to connect the electrical components of the new energy vehicle to realize the control of electronic and electrical components such as sensors / control units.

Automobile wire harness generally refers to wrapping copper wire, aluminum wire and other metal conductors with plastic hose and other materials, then crimping and fixing the wire harness connector with the wire harness pin, and binding the wire harness branches together by nylon tape.

Automobile wire harness is generally composed of cables, terminals, connectors, fixtures and other parts.

Cable is the main body of the automobile wire harness, and it is one of the key components that connect the electrical parts and transmit the electrical signals of the automobile.

Current carrying capacity is one of the important indicators in the selection of cables, which is mainly affected by wire diameter, wire length, resistivity and ambient temperature.

The connector is also known as the wiring harness connector, which is mainly used to effectively connect the cable with the electrical parts of the automobile to realize the function of wiring harness connection.

When the wire harness connectors are used in pairs, the male and female connectors are usually required to be used in complete sets, and the female connectors are often used at the end of the wire harness, so as to ensure the connection performance between the automobile wire harness and the electrical parts of the car, avoid the problem of virtual connection, etc., generally can not be used interchangeably.

In addition, when the automobile wire harness is actually arranged and routed, it is inevitable to come into contact with other automobile parts, so the wire harness wrapping protection material is indispensable.

According to the different protective materials, wire harness protection materials are usually divided into PVC tape, bellows, flannelette tape, sponge tape, cloth tape and aluminum foil tape.

The use of wire harness package protection materials is generally based on the use of the wire harness environment, temperature resistance requirements, wear resistance and so on.

Because the wire harness is a flexible connection and is in relative motion with the automobile parts all the time, the necessary fixing device is implemented to route the wire harness according to the designed direction, so as to avoid the confusion of the wire harness direction and affect the reliability of the wire harness.

The commonly used fixing devices of wire harness mainly include: rubber sheath, bandage, wire harness bracket, clasp and so on.

The wire harness fixing device assists the wire harness to move and fix, which is mainly selected and used according to the use environment, the nearby fixing device and so on.

The wire harness also includes fuses, labels, etc., which need to be selected according to the use conditions of the automobile wire harness.