The most common thing that I run across are switches, lights, and indicators installed in removable dash panels with no thought given to easily disconnecting them. The sampling process was often long as suppliers would order the components, assemble the harness, and then send samples of what they thought the customer wanted. Yup, I got it at Radio Shack. Car stereos have come a long way. Step-by-Step Step 1: Secure the harness so that the wiring is facing you. These products, which play important roles, are equivalent to blood vessels and nerves in the human body. Many options are available for the type of conductive material used, the stranding used to construct the conductor, and the plating applied to the conductive materials.
This deck has a really slick inter-face for iPods and accessories. Stranded conductors were developed as a means of overcoming the rigidity of solid wires and come in many variations, and the application of the assembly will determine which type of construction to use. In this case, you would need to use enough wiring to allow the switches to be easily unplugged from their respective harnesses in the event the center console needed to be removed for whatever reason. Step 7: I connected the remote output terminal to the trigger lead for the processor and amplifiers. This appears to be a standard.
Funny how that worked out, but it was certainly fitting. I built this circuit and harness from scratch. The hardest part of the job was drilling the holes in the door and body to get the wiring from the body and into the doors. Thermoset Wire and Cable Materials One of the most beneficial ways of distinguishing the characteristics of a wire or cable is to determine if the insulation or jacket material used is a thermoset or a thermoplastic. Many components will be involved in the assembly design and each component will have an impact on the performance of the finished cable assembly or wire harness. Our knowledge of materials, tooling and process flow enable us to offer our clients high quality harnesses at a competitive cost.
The switches can be located in the doors or centrally, such as in a center console. . Conclusion In conclusion, there are a number of factors to determine when designing a cable assembly or wire harness for your application. With advancing technology, there has been a much needed shift in the development process by incorporating the wire harness design in earlier stages. Notice that I secured the split loom tubing to the wiring in the jamb via the electrical tape method I shared with you in Chapter 6.
This foaming process will alter the insulation by creating air bubbles in the insulation allowing the passage of the high speed signal without being impeded. Another choice the cable assembly designer will need to make is whether a strain relief will be needed. When evaluating a new cable or wire harness solution, remember to carefully consider the specific environment it will be used in and the temperature and conditions it will be exposed to. Each conductor of the cable assembly should be designed for the specific use it will be expected to see. Meeting the needs of the automotive society in safety, comfort, and consideration for the environment The Sumitomo Electric Group operates its wiring harness business globally to offer various products that meet the needs of the times with superb technologies and quality. These steps make it a snap to add a keyless entry at some point down the road.
As you can see, I believe in having plenty of connectors on hand to choose from. Each component is designed to ensure reliable transmission of energy and information in the severe in-vehicle environment characterized mainly by high temperature, vibration, moisture, and noise. Step 4: Mount the relays. Keeping serviceability in mind, there may be times when something needs to be removed, such as the center console in the example I just gave. Of course this job also calls for all the regular wiring tools. We are set up to offer wiring harness manufacture with a design and development capability if required from the customer. Step 11: Secure the wiring away from moving parts, such as the window regulator and door lock mechanism.
Knowing that the key difference between a thermoplastic and thermoset is in the way they respond to elevated temperatures can be an important aspect of which material to choose. This particular characteristic is why thermosets are useful as durable materials that do not soften under high heat, such as car tires or flat roofing membranes. This chapter covers the last major topic—harness basics. They will probably just start cutting wires. Every specification of the design needs to be addressed upfront before manufacturing can begin. It is equally important to keep the bill of materials current as a minor change to a single wire can affect the harness material requirements, configuration, layout, tooling, and testing requirements.
This is because thermoset materials have a reduced likelihood of failure if momentarily operated at the higher temperatures that often accompany an overloaded conductor. The foil shield is the lowest cost to apply, has fairly good flexibility but not good flex life, and is good at higher frequencies but is less effective at low frequencies. Another option for an overall shield would be a braid shield. In addition to Safety and Environmental standards, assemblies may also need to meet Industry Standards based on specific performance criteria. If that is the situation then the connector choices will be very limited. The cabling serves several purposes, it provides for a more flexible assembly and it also produces a round configuration that will allow for an aesthetically pleasing end assembly.
Read our Case Study on Bus Manufacturer Optare. The table is a generalized summary that does not apply to every material. This needs to be addressed to ensure that my installation goes smoothly—better to do it at the bench. You always pay less per foot for a big roll than for a small roll, and this pays off in the long run. Materials are available to meet a broad range of applications and environments.