2-520261-1 Electronic Component Connectors Electrical Equipment Accessories Terminal connectors

2) Installation of wire harness penetration and rubber sheath

When making wire harness through holes, a common mistake is that the size of the via hole only considers the thickness of the wire harness, and ignores that the connectors on the wire harness also need to pass through the holes. This is very simple logic, but it is often made by beginners. mistake.

Opening holes in sheet metal is not a random decision. You need to consider the process of sheet metal opening and the requirements for sheet metal holes when installing the wire harness rubber sheath. Generally speaking, there are the following requirements:

The diameter of the connector with the largest outer envelope diameter must be smaller than the diameter of the sheet metal hole. The usual requirement is that the diameter of the sheet metal hole is at least 3 times the largest size of the connector. This requirement also applies to when the wire harness passes through a closed cavity, such as the cavity between the inner and outer panels of the tailgate, the cavity between the inner and outer panels of the side panel, etc. In the direction of the wire harness passing path, the cross-sectional diameter of the cavity space is greater than 1.3 times that of the connector

The corresponding via hole size of the rubber part must match the material thickness correctly, and the interference between the matching diameter of the rubber part and the sheet metal part shall be greater than 1 mm and less than 2 mm;

The sheet metal surface along the hole's radius within 6mm greater than the plugged hole must be smooth to ensure tightness.

3) Installation and fixation of connectors

Connectors are important electrical components on the wire harness assembly. When designing the wire harness layout, attention should be paid to the installation and fixation of the connectors. The main requirements are as follows:

A certain length of wire harness at the end of the connector needs to be reserved to facilitate the insertion and removal of the connector.

Regarding the reserved length of connectors, the focus is on the following: instrument clusters, switch panels, air-conditioning panels, sound systems, display screens, and other connectors connected to the instrument panel wiring harness, four-door switch wiring harnesses, and ceiling lights on the indoor ceiling. And switch wire harness, in addition, the wire harness plug-in on the sub-instrument, the wire harness plug-in under the seat and the wire harness and wire harness docking plug also need to be reserved in length.

According to the installation depth of the electrical device, the location of the socket, the direction of the socket opening and the rear space after the electrical device is assembled, and according to the convenience of operation, appropriately increase the reserved length of the connector on the wiring harness.

Reserved length L = electrical device installation depth h + electrical device panel width 0.7B + 100 (mm),

Among them: the installation depth h of the electrical device - refers to the distance from the external decorative surface to the internal electrical device connection socket after the electrical device is assembled; the panel width of the electrical device 0.7B - refers to 0.7 times the height of the decorative surface at the front of the electrical device.

When reserving length, special attention needs to be paid to abnormal noises and cuts and other damage to the wire harness. Damage to the wire harness can be avoided by adding anti-cut wrapping to the outside of the wire harness and anti-cut tape to the surrounding sharp parts, and reducing abnormal noise by wrapping it with sponge.

Due to vehicle differentiation, the wiring harness branches that are not used during assembly need to be bundled separately and fixed on the main line or bracket. When bundling the wiring harness, the minimum bending radius cannot be less than 2 times the diameter of the wiring harness.

Make sure that there is enough space for the plug-in installation. In the plug-in direction of the plug-in connector, there must be a space greater than twice the length of the plug-in direction.

Harness connectors should be arranged in a position that is easy to find, within reach as much as possible, and in a position that is easy to operate with hands and tools.

The docking connector needs to be fixed, and the fixing hole of the plug-in needs to be anti-rotation to facilitate the fixing of the plug-in.

The ground terminal on the wiring harness, the positive terminal such as the starter should be anti-rotation designed.

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