Basic introduction to automobile wiring harness

Issuing time:2020-03-05 00:00

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Automotive wire is also called the low voltage power lines, it has to do with ordinary
household electric wires are not the same. Ordinary household electric wires are
ChanRui copper wire, there is a certain hardness. The car more than copper wires are a
core soft lines, some fine soft wire such as hair, several or even dozens of annealed
copper wire wrapped in plastic insulation tube (PVC), soft and not easy to break.

Due to the particularity of the auto industry, automotive wiring harness manufacturing
process is better than other ordinary wire. The system in manufacturing automotive
wiring harness can be divided into two categories:
1. To European and American countries, including China: To control the manufacturing
process by using TS16949 system.
2. Mainly to Japan: Such as Toyota, Honda, they have their own system to control the
manufacturing process.

With the increase of car function, widespread application of electronic control

technology, more and more electrical parts, wires will be more and more, the heavier
wire also becomes thicker. The car that is so advanced introduces CAN bus
configuration, the multiplex system. Compared with the traditional wiring harness, multi-
channel device greatly reduces the wire and the number of plug-ins, make the wiring
more easily.

The commonly used

Automotive wiring harness commonly used specifications of wire nominal cross-sectional
area 0.5, 0.75, 1.0, 1.5, 2.0, 2.5, 4.0, 6.0 mm2 wire (Japanese that is commonly used in
nominal cross-sectional area is 0.5, 0.85, 1.25, 2.0, 2.5, 4.0, 6.0 mm2), they are allowed
to load current value, with different power wire of electrical equipment. In the case of the
vehicle wiring harness, line 0.5 specification applies to the instrument lights, lights, door
lights, dome light, etc.; Before and after 0.75 specifications apply to the license plate
lamp, little lamp, brake lamp, etc; 1.0 specifications line is suitable for the lights, fog
lamps, etc.; 1.5 specifications line is suitable for the headlamps, horn, etc.; Lord, take
the power cord such as generator armature wire for 2.5 to 4 mm2 wires. This just refers
to general motors, the key depends on the load of the maximum current value, such as
battery by iron wire, the positive power cord is a special car wire used alone, both wire
diameter is larger, there are at least ten square millimeter above, these "big MAC" wire
will not be codified in the main beam.

arrangement
In front of the permutation wiring harness prior to map wiring harness, wiring harness
diagram and circuit principle diagram is not the same. Circuit principle diagram is
describe the various electrical part of the relationship between the image, it does not
reflect the electrical parts how to connect with each other, not affected by the size of the
various electrical components shape, and the influence of the distance between them.
And wiring harness plan must consider the size of the various electrical components
shape and the distance between them, also want to reflect the electrical parts is how to
connect to each other.

Wiring harness factory technicians according to the wiring harness diagram to make wire
line after line board, workers in accordance with the regulations of the discharge line
board to cutting line line line. Vehicle main beam generally divided into engine, power
generation, and start (ignition, ems), instrumentation, lighting, air conditioning, auxiliary
appliance parts, such as a branch of main beam and wire harness. More than a vehicle
main beam has branch wire harness, like tree trunk and branches. Vehicle main beam
often dashboard as the core part, and extend. Because length relationship or assembly
is convenient wait for a reason, some automotive wiring harness into car wiring harness,
including instrumentation, air conditioning, battery, engine, before the light assembly),
the rear of the wiring harness (taillight assemblies, license plate lamp, trunk lamp), tent,
wiring harness, dome light, speakers (door), etc. Wire on each end will sign on Numbers
and letters, to indicate the wire connection object, the operator can see mark properly
connected to the corresponding wiring and electrical device, which is especially useful
when repair or replace the wiring harness. At the same time, the color of the wire can be
divided into monochrome lines and double color lines, color also has a regulation, the
purpose of the general is defined standards. Industry standard in China was the main
color, such as regulations, dedicated to a single black iron wire, red solid color used for
the power cord, do not confuse.

XianShuYong woven wire or plastic adhesive tape package, for security, processing and
convenient maintenance, woven wire packages have been eliminated, it is with plastic
adhesive tape. Between the wire and wire harness, wire harness and the connection
between the electrical parts, using plug-in or line ear. Plug-in made from plastic, a plug
and socket. Between the wire and wire harness with united into the plug-in, the
connection between the wire and the electric parts with al plug-in or ears.

material
The material requirements of automotive wiring harness is also very strictly:

Sporadic including its electrical properties, material, temperature tolerance, etc., are
higher than general wiring harness requirements, especially involving security: such as
direction, brake control system the important component of wiring harness, more strict.

Analysis of a practical automotive wiring circuit

1-Identify each of the major elements in the above automotive wiring diagram. Starter
Battery Distributer Ammeter Generator Junction box Breaker Fuse Foot selector switch
2-Explain the purpose and working of any three elements briefly. Battery- purpose-
Batteries are small essential components to…
 1-Identify each of the major elements in the above automotive wiring diagram.
 Starter
 Battery
 Distributer
 Ammeter
 Generator
 Junction box
  Breaker
 Fuse
 Foot selector switch

2-Explain the purpose and working of any three elements briefly.

Battery-
purpose-Batteries are small essential components to operate many devices. It is one of
the key components in our day-to-day life. Some batteries are rechargeable batteries
and are used in each and every sector. Below are some of the applications of batteries.
 Automotive
 House
 Health Instruments
 Medical
 Logistics and construction
 Firefighting and Emergency
 Military
Electric Vehicle Battery is commonly used in vehicles. This battery is used to power the
electric motors of electric vehicles. The batteries of electric vehicles are usually
rechargeable. Generally, lithium-ion batteries are used in electric vehicles.
working-
 A battery is a device that stores chemical energy and converts it to electrical
energy.
 The chemical reactions in a battery involve the flow of electrons from one
material (electrode) to another, through an external circuit.
 The flow of electrons provides an electric current that can be used to do work.
 To balance the flow of electrons, charged ions also flow through an electrolyte
solution that is in contact with both electrodes.
 Different electrodes and electrolytes produce different chemical reactions that
affect how the battery works, how much energy it can store and its voltage.

Generator- is also called a dynamo, it converts mechanical energy into electricity for
transmission and distribution over power lines to domestic, commercial, and industrial
customers. Generators also produce the electrical power required for
 automobiles
 aircraft
 ships
 trains
Working-
Generators don’t actually create electricity. Instead, they convert mechanical or
chemical energy into electrical energy. They do this by capturing the power of motion
and turning it into electrical energy by forcing electrons from the external source through
an electrical circuit. A generator is essentially an electric motor working in reverse.
Some electrical generators, such as those at Hoover Dam, for example, are huge and
provide enormous amounts of energy by transferring the power created by water turning
turbines into electricity. Residential and commercial generators however are much
smaller and rely on more traditional fuel sources like diesel, gas, and propane to create
mechanical power that can then be forced into a circuit and induce an electrical current.
Fuse-
purpose-
The fuse breaks the circuit if a fault in an appliance causes too much current to flow.
This protects the wiring and the appliance if something goes wrong. The fuse contains a
piece of wire that melts easily. If the current going through the fuse is too great the wire
heats up until it melts and breaks the circuit
 Acts as a barrier between the electric circuit and the human body
 Prevents device failure due to faulty circuit operation
 The fuse prevents short circuits
 Prevents overload and blackouts
 Prevents damage that is caused due to mismatched loads
The markings on the fuse carry information such as the Ampere rating, voltage rating,
and interruption rating.

Working-
The fuses work on the principle of the heating effect of the current. It’s made up of thin
strip or strand of metallic wire with noncombustible material. This is connected between
the ends of the terminals. Fuse is always connected in series with the electrical circuit.
When the excessive current or heat is generated due to heavy current flows in the
circuit, the fuse melts down due to the low melting point of the element and it opens the
circuit. The excessive flow may lead to the breakdown of wire and stops the flow of
current. The fuse can be replaced or changed with the new one with suitable ratings.
The fuse can be made up of the element like zinc, copper, silver &aluminum. They also
act as a circuit breaker which is used to break the circuit when the sudden fault occurs in
the circuit. This is not only a protector but it is also used as a safety measure to prevent
humans from hazards. So this is how the fuse operates.
3-If the total load is 10A from battery, what should be the fuse rating?
we can use 13A fuse for above given question

4-If 500W is the load, what is the voltage and capacity of battery you recommend?
Capacity=load*time
load given=500watt
Time =24hours
average of voltage= 12v

capacity=500*24=12000wh
Amp-hours = Watt-hours / Volts
=12000/12=1000AH

5-Identify any two elements which are connected parallel to each other. Why they are
connected in parallel
Asper the above image Generator with current voltage and regulaterare connected in
parallelif two are more components are connected in parallelthe have the same
differential of potential voltage across their ends.

6-Identify any two elements which are connected in series. Why they are connected in
series
as per the above image battery and starter are in series to each other because same
current flows throw them.