What?: Wiring harness essentials components and how it is manufactured?
Objective: This article will give you practical exposure of wiring harness and its components. In the end of article , you will be able to understand below topics.
Different roles in Automobile (Wiring Harness):
There are different roles and responsibility in wiring harness.
1.System engineering: This position is in charge of the vehicle’s component integration. System engineers are in charge of packaging, architecture, and component development.
Taking one example of Lighting in vehicle, In lighting also if I will take very specific i.e Headlamp.
System engineer will responsible to define the specification of Headlamp, Packaging location and integration of other CFT.
Roles in Electrical Engineering:
Introduction: Understanding of Wiring harness
The wiring harness is bundle of electrical wires, that connects all electrical and electronic (E/E) components in the vehicle, like sensors, electronic control units, batteries, and actuators.
The wiring harness transfers energy and signal within the E/E system to fulfill primary functions, such as steering and braking as well as secondary car functions, such as ventilation and infotainment.
Wiring Harness used in different industry like Aerospace, automotive, medical, telecommunications, Information technology, construction, Robotics & automation and manufacturing etc..
Before directly jumping to create the schematic, Harness team gets Product specification/Technical specification/Feature list from project management Team then Harness team starts their activity based on feature list.
What is Feature list/Product specification:
Your vehicle’s feature list describes your vehicle. It provides you with an overview of the features that your car will have. Take the massager function, for instance: is your car compatible with this feature?
If a specific function is applicable then which variant used that function, i.e., Base, Mid, High, etc.
In below Features list, we have different brands of car but when we work on one project then we can have different variant like Base ,Mid, High etc…
Taking one feature like Keyless entry, This feature might not be applicable for Base and Mid variant but its applicable for High variant in same project.
Wiring harness design process:
Different Layouts in Wiring Routing:
Upcoming Topics in this article:
Electrical Device selection and schematic
Selection of Wire with practical example:
Different standard of Wires:
How to select connector in Wiring Harness?
we have written the article on Connector . you can read it here: How to select connector in wiring harness?
Types of different connectors:
Terminal and its Type:
Terminal Plating:
Protection and Insulation used in wiring Harness.
How to select Fuse and type of fuse.
What is Relay and how to select relay?
How to calculate Bundle Diameter?
What is FMEA?
What is DVP?
Different types practical field issues.
You can check out the video on Basics of Wiring Harness.