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First, the structure of the plug-in

① Waterproof connector should achieve the effect of waterproof and dust-proof. Generally, it can be divided into integral seal and single-hole seal, the latter is more commonly used; The sealing material used can be: rubber sealing plug and glue sealing, the former is more commonly used.

② The connector with the connecting mechanism has the advantage of making the connector fixed more convenient, avoiding the noise generated by the connector without fixing, and making the link more reliable. It can be divided into direct connection and buckle connection.

The buckle of the buckle is divided into the following types:

a. The jacket comes with a buckle

b. The sheath itself has a hanging position, you can hang the external buckle, the external buckle is generally divided into the following:

Note: When selecting the buckle, the thickness of sheet metal suitable for the buckle should also be considered.

c. The sheath can be connected to each other

③ The connector with the card lock mechanism has the advantage of making the connection between the line and the line or between the line and the electrical parts more firm and preventing loosening. Generally used in the engine, wiper motor and other bumpy vibration environment. The card lock mechanism in the form of connectors generally have the following types.

(4) A connector with a crimped wire cover can ensure that the crimped wire at the end of the connector inserted into the connector will not shake unnecessarily at the root of the connector, reduce the shear force of the differential vibration on the wire, and improve the quality of the wiring harness.

Principles for selecting plug-ins:

(1) The selection of connectors should ensure good contact with electrical parts, reduce the contact resistance to the lowest level, improve reliability, limited selection of double-spring compression structure of the connector.

② Choose the size of the connector reasonably according to the cross-sectional area of the wire and the size of the passing current.

(3) In the engine room, chassis and other harsh environment of the butt sheath, due to the temperature, humidity and there are a lot of corrosive gases and liquids, so must? Waterproof sheath, the vacancy shall be sealed with a waterproof plug. At the same time, attention should also be paid to the choice of sheath material, such as flame retardant performance.

(4) Try to avoid using the same sheath in the same docking area. If it is impossible to avoid, it needs to be distinguished by different colors.

Based on the overall coordination of the car appearance, black or dark sheathing should be preferred in the engine compartment.

⑥ In order to reduce the type and quantity of wire harness butt sheathing, mixed parts are preferred to make the assembly fixed easily.

The door harness and the body harness docking, the best choice of the card lock mechanism connector, to ensure that the door frequently open and close, avoid the phenomenon of docking loose.

⑧ in order to save cost, low safety grade of electrical equipment to choose to meet the performance requirements of the domestic parts, in addition to the floor can choose non-waterproof sheathing.

⑨ High temperature resistant nylon sheath should be used for connectors from high temperature parts of engine room.

⑩ Different types of connectors can carry the following current: (for reference only)

? According to different needs to choose different materials of connectors, according to the actual situation in the plastic to add flame retardant or reinforcing materials, in order to achieve the purpose of strengthening or flame retardant, such as adding glass fiber reinforcement.

Two, wiring harness fixation and installation

The wire harness on the vehicle, mostly uses the wire card of the wire harness to complete the fixing, the following is a brief introduction to several commonly used fixed card points.

1. Cable tie buckle

Matching size: 7*12 long round hole.

Scope of application: body, frame, sheet metal parts, interior parts, etc.

Features: Wide application range, flexible installation and disassembly, and prevent wire harness rotation.

2. Cable tie clip with pipe clamp foot

Matching size: 7*12 long round hole.

Scope of application: Cover part of interior trim of car body.

Features: On the basis of the ordinary cable tie buckle, the pipe clip is added, which is conducive to the direction and fixation of the washing pipe, the handbrake cable and the engine room cover cable.

3, with tooth tie buckle

Fitting size: M6 stud

Scope of application: welding bolts for body and frame

Features: Flexible installation and disassembly, can be fixed thicker wiring harness

4. Right Angle buckle

Matching size: 7*12 long round hole

Scope of application: body, frame, sheet metal parts, interior parts, etc

Features: Flexible installation and disassembly, and prevent wire harness rotation, suitable for wire harness installation surface and fixed point is not on the same plane state.

5. Plate buckle

Matching size: 7*12 long round hole

Scope of application: body, frame, sheet metal parts, interior parts, etc

Features: The harness has good directivity, and prevents the harness from turning.

6, plate offset buckle

Matching size: 7*12 long round hole

Scope of application: body, frame, sheet metal parts, interior parts, etc

Features: The wiring harness has good directivity, and prevents the rotation of the wiring harness, which is convenient for the installation of the wiring harness deviating from the fixed point.

7. Sheet metal clip

Scope of application: body sheet metal, interior panels, etc

Features: It is suitable for sheet metal and interior parts that are not convenient to open holes

8. Lock hole type buckle

Matching size:

Scope of application: On the interior panel, mainly used for connecting and fixing

Features: Prevent plug - in rotation, and avoid misinsertion

9. Anti-rotating terminal

Fitting size: M6 welding nut, 6*6 square hole

Scope of application: Wire harness fixed on the body and frame of the car

Features: Prevent rotation, good directivity.

10. A pillar connector fixed bracket

Matching size: board thickness of 0.9mm&7*12 long round hole &11.5*16 long round hole, fixed at three points

Scope of application: Fixed front instrument wiring harness and floor wiring harness, indoor light wiring harness, front door wiring harness docking parts

Features: As the butt parts of the more concentrated area of the unified fixed

Iii. Precautions for wiring harness arrangement and bandaging

(1) Increase the bending radius as much as possible, avoid sharp corners, avoid friction and high temperature;

(2) The wiring harness joint shall not turn too sharply, which can ensure the performance of the wiring harness seal;

(3) Arrange the connectors horizontally as far as possible to make the water discharge smooth;

(4) The clamping point should not be too close to the connector;

(5) Fix the connectors on the structural parts as far as possible;

(6) The central electrical box is generally fixed with steel plate strips, bolts, etc., or the fixed structure designed by the electrical box itself is directly installed on the car body;

(7) duct tape is usually used in the driving room to wrap at intervals;

(8) The instrument panel is usually tightly wrapped with adhesive tape;

(9) On the floor or far away from the engine, the general use of flame retardant corrugated pipe bandage;

(10) The interior of the door and the interior of the luggage compartment are generally wrapped with adhesive tape or industrial plastic sheets;

(11) In some areas close to the engine, heat-proof glass sleeve or wire harness is used to wrap the glass ribbon;

(12) Pay attention to the distance between the anti-theft ECU and the read and write coil to prevent signal transmission attenuation.