Low Voltage Wiring Harness

Low Voltage Wiring Harness is an important component of automotive electrical systems, especially playing a crucial role in new energy vehicles. The following is a detailed analysis of low-voltage wiring harnesses:

1、 Definition and Function

Low voltage wiring harness refers to a collection of wires, cables, connectors, and other electrical components used to transmit signals and power at lower voltages. It connects various sensors, electronic control units (ECUs), display screens, onboard communication systems, etc. in the car to transmit data, communication signals, and control signals to support the normal operation and performance monitoring of the car.

2、 Structure and Composition

Low voltage wiring harnesses typically consist of the following parts:

Wires and cables: responsible for transmitting electrical signals and power, the specifications and materials of wires and cables may vary depending on the transmitted signal.

Connector: an interface used to connect wires, cables, and electronic devices to ensure accurate signal transmission.

Protective materials: such as tape, sheath, etc., used to protect wires and cables from external environmental damage.

Fixed devices: such as buckles, zip ties, etc., used to secure wire harnesses and prevent them from becoming loose or damaged during use.

3、 Characteristics and Requirements

High reliability: Low voltage wiring harnesses need to have high reliability to ensure stable signal transmission during long-term use, without breakage or failure.

Lightweight design: In order to reduce the weight of the entire vehicle, improve energy efficiency and range, low-voltage wiring harnesses are usually designed with lightweight.

Strong anti-interference ability: Automotive electrical systems are sensitive to electromagnetic interference, so low-voltage wiring harnesses need to have strong anti-interference capabilities to ensure accurate signal transmission.

Wear resistance and corrosion resistance: Due to the fact that low-voltage wiring harnesses are usually located inside cars and need to withstand various harsh environments, they need to have good wear resistance and corrosion resistance.

4、 Application and Classification

Low voltage wiring harnesses are widely used in various automobiles, especially in new energy vehicles. According to their functions and connection methods in automobiles, low-voltage wiring harnesses can be divided into various types, such as power wiring harnesses, signal wiring harnesses, sensor wiring harnesses, charging wiring harnesses, and auxiliary wiring harnesses.

Power harness: used to transmit high-voltage power and connect power system components such as battery packs and electric motors. Although mainly transmitting high-voltage electricity, in some cases, the power harness may also contain low-voltage signal lines for monitoring and controlling the status of the power system.

Signal harness: used for transmitting data, communication signals, and control signals, connecting various sensors, ECUs, display screens, etc. These signals are crucial for the normal operation and management of automobiles.

Sensor wiring harness: specifically used to connect various sensors, such as temperature sensors, speed sensors, etc., to monitor the status of the car and provide feedback to the control system.

Charging harness: used to connect charging plugs, charging controllers, and battery charging interfaces, undertaking the charging task of electric vehicles.

Auxiliary wiring harness: generally used to connect other automotive systems, such as air conditioning systems, audio systems, etc.

5、 Design and Testing

The design of low-voltage wiring harnesses needs to consider multiple factors, such as the specifications of wires and cables, the selection of connectors, the choice of protective materials, and the design of fixing devices. In the design process, it is necessary to fully consider the actual usage environment of the car and the requirements of the electrical system to ensure the reliability and safety of the low-voltage wiring harness.

At the same time, the inspection of low-voltage wiring harnesses is also an important part of ensuring their quality. The testing content includes but is not limited to the conductivity of wires, contact resistance of connectors, integrity of protective materials, and firmness of fixing devices. Through rigorous testing, potential quality issues can be identified and repaired in a timely manner, ensuring the normal use of low-voltage wiring harnesses in automobiles.