What is the theoretical basis of manufacturing and assembly in automotive wiring harness?

Automotive wiring harness is the network main body of automobile circuit, and there is no automobile circuit without wiring harness. The wiring harness refers to the assembly that uses wires and cables to press the contact terminals (connectors) made of copper, and then presses the insulators or adds a metal shell outside, and forms a connecting circuit by bundling the wiring harness. The harness industry chain includes wires and cables, connectors, processing equipment, harness manufacturing and downstream application industries. The wire harness is widely used in automobiles, household appliances, computers and communication equipment, and various electronic instruments and meters. The body harness connects the whole body and is generally H-shaped.

Automobile wires, also known as low-voltage wires, are different from ordinary household wires. Ordinary household wires are copper single-core wires with certain hardness. The car 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 (PVC), which are soft and not easy to break.

Due to the particularity of the automobile industry, the manufacturing process in automotive wiring harness is more special than other ordinary wire harnesses.

Automotive wiring harness manufacturing system can be roughly divided into two categories:

1. By European and American countries including China:

TS 16949 system is used to control the manufacturing process.

2. Mainly in Japan:

For example, Toyota and Honda have their own systems to control the manufacturing process.

With the increase of automobile functions and the wide application of electronic control technology, there are more and more electrical components and wires, and the wiring harness is getting thicker and heavier. Therefore, all limousines have introduced CAN bus configuration and adopted multiplex transmission system. Compared with traditional wire harness, multiplexer greatly reduces the number of wires and connectors, making wiring easier.