Wire harness design is a complex and multifactorial engineering task that requires comprehensive consideration of electrical performance, environmental adaptability, mechanical protection, cost, and other aspects. The following are key factors to consider in wire harness design:

1. Electrical requirements

Current and voltage: The wiring harness must be able to carry the expected current and voltage, avoiding overload and voltage drop

Power requirements: Select the appropriate wire size and insulation material based on the power requirements of different components

2. Environmental factors

Temperature range: The wiring harness needs to operate normally within the working temperature range, including extreme high and low temperatures

Humidity and corrosion: Wiring harnesses may be exposed to moisture and chemicals, requiring the use of corrosion-resistant and waterproof materials

Vibration and shock: Cars will experience vibration and shock during driving, and the durability and reliability of the wiring harness should be ensured during design

3. Mechanical protection

Insulation material: Choose appropriate insulation materials to prevent short circuits and electric shocks

Sheath and wrapping: In order to prevent wear, chemical corrosion, and physical damage, wire harnesses usually require protective sheaths or wrapping layers

Fixed and supported: When designing, it is necessary to consider the fixing and supporting methods of the wiring harness to avoid damage caused by vibration or collision during use

4. Installation space

Wiring channel: The design of the wiring harness needs to consider the wiring channel inside the car to ensure that it can be installed smoothly and will not interfere with other components

Space utilization: When designing wiring harnesses, it is necessary to consider the space limitations inside the car and arrange the harnesses reasonably to maximize the use of space

5. Maintainability

Easy to maintain: The maintainability of the wiring harness should be considered during design to facilitate later inspection and maintenance

Identification and Separation: Simplify the installation and maintenance process through clear identification and separation

6. Security

Anti electromagnetic interference (EMI): The design of wiring harnesses should consider electromagnetic compatibility to prevent the impact of electromagnetic interference on electronic devices

Short circuit protection: Measures to prevent short circuits should be considered in the design, such as reasonable insulation and sheath design

7. Compliance and Standards

Industry standards: Wire harness design needs to comply with relevant industry standards and regulations, such as ISO, SAE standards, etc., to ensure that it meets safety and quality requirements

Certification requirements: Some markets or vehicle models may have additional certification requirements, which need to be considered during design

8. Material selection

Wire material: Choose appropriate wire materials (such as copper or aluminum) to ensure good conductivity

Insulation and sheath materials: choose materials with good heat resistance, wear resistance, and corrosion resistance

9. Protection level

Waterproof and dustproof performance: The wiring harness needs to have good waterproof and dustproof performance to ensure the normal operation of the automotive electrical system

Testing method: The standard needs to specify the waterproof and dustproof levels of the wiring harness, as well as the corresponding testing methods and requirements

10. Durability and reliability

Life testing: Wiring harnesses need to withstand long-term vibrations and high temperatures, and standards need to specify the methods and requirements for testing the lifespan of wiring harnesses

11. Environmental performance

Material environmental friendliness: The materials used in the wire harness need to meet environmental requirements, and corresponding requirements need to be put forward for the recycling and reuse of the wire harness