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In recent years, the weight of the car has become a research hotspot has become a direction of research now, this article on the development of automotive wiring harness trends, selection and vehicle wiring harness all kinds of layout on the impact of vehicle weight Brief analysis, and the development trend of the future of lightweight wiring harnesses.

The wiring harness is lightweight

Wire harness as an integral part of the car assembly, the weight of the vehicle harness also accounts for about 5% of the weight of the vehicle. As the main component of the vehicle wiring harness - wire, its selection and development trend of the harness light weight plays a decisive role.

1, the development and application of aluminum wire

Aluminum is now the main rival in the field of low-voltage conductors for high-voltage conductors and automobiles. Although aluminum is slightly inferior to copper in terms of conductivity and safety, but with the rise in copper prices and the advancement of aluminum and advances in technology, Began to gradually use aluminum. Aluminum wire promotion is also a trend in the future development of automotive wire.

Most of the automotive wire is considered to have a minimum cross-sectional area of 0.5 mm2 because of the mechanical strength of the wire. However, from the current analysis of the Japanese wiring harness wire harness, some models have begun to use 0.35mm2 wire, 0.35mm2 wire instead of 0.5mm2 wire, the same unit length will save 30% of the weight.

From the wire assembly structure to analyze, 0.35mm2 wire in the outer insulation layer and the wire diameter of the wire can meet the mechanical properties of the wiring harness requirements.

2, wire cross-sectional area selection to consider lightweight

The outer insulation layer of the wire harness is also continuously innovated so that the weight of the wire is reduced and the performance is improved. At home and abroad at the current line by line, there are thick leather line, shielded wire, coaxial line, high temperature crust line, thin line and so on. In some signal fidelity requirements of relatively high demand for electronic equipment, electronic equipment suppliers usually require some excellent shielding lines for signal transmission, the requirements are usually much more than the actual demand, so from the price, cost To consider, we can also use the same performance as the excellent wire replacement shield wire and the like heavy quality, high prices of wires, such as CAN bus, CAN bus in the physical layer definition inside, there are two kinds of wires can choose: shielding Wire and twisted pair, if the CAN system, requires the use of shielded wire, CAN bus involved in the whole car ECU, because of its bus node branch is also more, the part of the shield wire caused by the weight is obvious, but according to the actual situation, Outside the development of the CAN system are 0.35 square twisted pair to carry out signal transmission, and can guarantee the fidelity of signal transmission.

Lightweight considerations when wiring harness is arranged

compartment harness, The center saves the connection between the dashboard harness and the backplane harness, the connection of the dashboard harness to the engine compartment harness, the connector that connects the dashboard harness to the ceiling harness, and also saves the associated brackets of the connector.

1, the impact of the floor wiring harness on the lightweight

The layout of the floor harness can also be divided into H-type arrangement, h-type arrangement, E-type layout and other different arrangements, each layout of the wiring harness lightweight also has a certain impact, according to the layout of the wiring harness The arrangement of the approximate shape, and these arrangements are in the body floor, the body floor of the wiring harness connector and the weight of the fixed bracket is also very objective for the wiring harness. The various arrangements described below have an impact on vehicle weight reduction.

The H-type arrangement is a preferred arrangement for the wiring harness arrangement because the H-type wire harness arrangement takes care of the full range of the vehicle's electrical appliances and because both the arrangement and the dashboard harness are carried out at both ends Connection, docking connector space reservation is very large, but in the lightweight aspects of some limitations.

H-type arrangement of the use of floor wiring harness and instrument panel wiring harness leaving only one interface, the harness at both ends of the interface integrated into one, the wiring harness and the floor of the docking of the high degree of integration, space reserved compact, to a certain extent, reduce the floor harness weight, But if the pre-definition of the design is better, the future changes are not the case to consider this approach is better.

2, the impact of the cabin wiring harness on the lightweight

The layout of the engine compartment harness is also divided into H-type arrangement, C-type arrangement, F-type arrangement. Due to the cabin fuse, the relay box is generally integrated in the engine compartment wiring harness,
C-type arrangement is also in the light of the better, C-type layout in the dash board only open a hole, while using only a fuse, the relay box design, in the engine compartment on the right side of the electrical device is not much , The C-type layout is reasonable, while saving a certain number of harness components and wire length.

At present, the most popular F-type arrangement, that is, a branch of the engine compartment harness from the engine compartment dash through the board, one is arranged from the left side of the engine compartment in the past, all the electrical equipment in series. This arrangement is reasonable, but from the production of the harness weight is a moderate solution.

The Development Trend of Automobile Wire Harness Lightening

At present, the wide application of CAN data bus, the wiring harness wiring is more simplified, more compact structure, can reduce the weight, but also reduce costs, and therefore become a beam of lightweight development trend.
Wire harness technology in the continuous development, with the increasing demand for the market, the wiring harness is also imperative, the contents of the wire harness in the light of some of the trends and the overall arrangement of the impact of lightweight wiring harness, Research on lightweight research and technical research is also endless.