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Talk about automotive wire harness in details - JMK
 2023-05-10  189

Automotive wire harness, also known as low-voltage wires, are different from ordinary household wires, automotive wire harness are all copper flexible cords. Some flexible wires are as thin as hair, and several or even dozens of flexible copper wires are wrapped in plastic insulated pipes (PVC), which are soft and not easy to break. Because of the particularity of the automotive industry, the manufacturing process of automotive wire harness is also more special than other general wire harnesses.


The system of making automotive wire harness can be roughly divided into two categories:

1. Distinguished by European and American countries:
Use TS16949 system to control the production process.


2. Mainly Japan:
Such as Toyota and Honda, they have their own systems to control the process.
With the addition of car functions and the widespread use of electronic control skills, there will be more and more electrical parts, more and more wires, and the wire harness will become thicker and heavier. Therefore, the advanced car introduces the CAN bus equipment and chooses the multiplex transmission system. compared with the traditional wire harness, the multiplex equipment greatly reduces the number of wires and connectors, making wiring easier.

automotive wire harnesswire harness machine


Commonly used automotive wire harness.

The common specifications for wires in automotive harness are wires with a nominal cross-sectional area of 0.5, 0.75, 1.0, 1.5, 2.0, 2.5, 4.0, 6.0 square millimeters (the nominal cross-sectional areas commonly used in Japanese cars are 0.5, 0.85, 1.25, 2.0, 2.5, 4.0, 6.0, etc.), each of which has allowable load current values. Wires used in electrical equipment of different power. Take the whole vehicle harness as an example, 0.5 specification line is suitable for exterior lights, indicator lights, door lights, top lights, etc.; 0.75 specification line is suitable for license plate lights, front and rear small lights, brake lights, etc.; 1.0 specification line is suitable for turn lights, fog lights, etc.; 1.5 specification lines are suitable for headlights, loudspeakers, etc.; main power lines such as generator pivot line, iron wire and other requirements 2.5 to 4 square mm wire.


This only refers to one. As far as cars are concerned, the key depends on the maximum current value of the load. For example, the iron wire of the storage battery and the positive power cord are used by special car wires alone, and their wire diameters are relatively large, at least more than ten square millimeters. These "giant" wires will not be incorporated into the main wire harness.

Wire Harness Route

Draw the harness diagram beforehand before placing the harness. The harness diagram is different from the circuit schematic diagram. The circuit schematic diagram is a picture that describes the relationship between the various electrical parts. it does not reflect how the electrical components are connected to each other, and is not affected by the scale and shape of the various electrical components and the spacing between them. The harness diagram must not only take into account the size and shape of the electrical components and the spacing between them, but also reflect how the electrical components are connected to each other.


After the technician of the harness factory made the harness wiring board according to the harness diagram, the workers cut the wire according to the rules of the wiring board.

The whole car main wire harness generally distributes bonus engine (ignition, electric injection, power generation, starting), appearance, lighting, air conditioning, auxiliary appliances and other parts, with main wire harness and branch wire harness. A whole automotive owner wire harness has multiple branch harnesses, as if the tree stem is the same as the branch. The main wire harness of the whole car is often outside the panel as the core part, extending back and forth.


Because of length connection or convenient assembly, some cars' wire harness distributes red front harness (including appearance, engine, front light assembly, air conditioning, battery), rear harness (taillight assembly, license plate light, suitcase light), tent roof harness (door, headlight, stereo speaker) and so on. Each end of the harness is marked with numbers and letters to indicate the connection target of the wire, and the operator sees that the sign can be correctly connected to the corresponding wire and electrical equipment, which is especially useful when repairing or replacing the harness. Together, the color of the wire is divided into monochromatic and bichromatic lines, and the usefulness of color also has rules, which are generally self-defined by the car factory.

The harness is wrapped in woven thread or plastic adhesive tape. for safety, processing and repair convenience, the woven thread package has now been screened and is now wrapped in adhesive plastic tape. For the connection between wire harness and wire harness, and between wire harness and electrical parts, plug-ins or wire ears are selected. The connectors are made of plastic and are divided into plugs and sockets. The connection between harness and harness is connected by plug-in, and the connection between harness and electrical parts is connected by plug-in or wire lug.


JMK Automotive Wire Harness Machine Manufacturer

Shenzhen JMK Mechanical and Electrical Co., Ltd. specializes in the research and development of wire harness robots for 14 years, national high-tech enterprises, invention patents, 4Apens 5A ISO certification enterprises (industry certification standards), production and sales of high-tech enterprises. In 2004, it formally set up an assembly factory in Chinese mainland, and has become a large-scale production base of Chinese mainland fully automatic wire harness robot. JMK combines Japanese, Swiss, American and native wire harness processing robots with a new Chinese concept. An efficient, high-class and cost-effective wire harness processing robot has been developed in Chinese mainland.


The industrial chain is divided into four parts:
1. New energy vehicle wire harness processing robot.
2. Smart phone harness (Type-c) whole line processing robot.
3. Intelligent home appliance wire harness processing robot.
4. Automatic pipelined robot on AC line.

Both hardware and software have reached the most advanced level in the world. JMK new slogan: new quality, new service, the highest cost performance. Focus on the choice of partners from the starting point of quality!

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