13735454 Delphi Connector Waterproof Plug Seal For Automotive Connectors

4.2.3 Optimization of wire types

At present, there are generally four types of wires used in wire harnesses according to customer standards, namely Japanese wires that comply with JASO standards, German wires that comply with VW or DIN standards, wires that comply with ISO 6722 international standards, and wires that comply with national standard GB/T 25085. Among them, Japanese and German wires are the most commonly used. By calculating the current carrying capacity and adding some specifications or supplementing different specifications of wires that meet other standards while meeting the requirements of usage functions, the cost of wire harness components can be reduced while also contributing to the overall weight reduction of the vehicle.

Table 1 takes the German standard FLR type wire as an example (wire specifications are in mm2), and the wire specifications within the marked interval have a larger span. If some specifications are added between the span of the above specifications or Japanese standard wires are used, it can effectively supplement the range of wire specifications, as shown in Table 2.

Although there are structural differences between German and Japanese standard wires of similar specifications, German standard wires have advantages in cross-sectional area and conductor resistance, but the differences are not particularly significant. Japanese standard wires have certain advantages in terms of finished outer diameter and quality, as shown in Table 3.

1) Differences in temperature rise and current curves between German standard wires (Figure 4) and Japanese standard wires (Figure 5) of similar specifications.

From the temperature rise and current curves of two types of wires, it can be seen that under the same temperature rise conditions, the current carrying capacity of the German standard wire is slightly stronger than that of the Japanese standard wire. For example, when the temperature rise is 20 ℃, the difference in current carrying capacity between different specifications of wires is between 8.33% and 9.52%. The lower the temperature rise, the smaller the difference in carrying capacity.

2) The difference in smoke generation time between German standard wires (Figure 6) and Japanese standard wires (Figure 7) of similar specifications.

From the smoke generation time curves of two types of wires, it can be seen that under the same overcurrent conditions, the smoke generation time of German standard wires is longer than that of Japanese standard wires. The difference in smoke generation time between different specifications of wires is between 13.79% and 17.44%, and the smaller the overcurrent, the smaller the difference in smoke generation time.

Based on the comparison of various indicators of the two types of wires (Table 4), after sufficient design verification, adding some wire specifications that meet the requirements of this type of wire or using different specifications of wires that meet other standards will have more space for selecting wire specifications during design and can meet the requirements of some costs and self weight.

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