How to choose wire harness materials and avoid faults caused by wire issues
Jan 17,2024
1、 Principles for selecting electronic wiring harness materials
The selection of electronic wiring harness materials should comprehensively consider the following factors:
Electrical performance: The wire should have sufficient conductivity, voltage resistance, and anti-interference ability.
Mechanical properties: The wire should have good mechanical properties such as bending, stretching, and shearing.
Environmental adaptability: The wire should be able to withstand factors such as temperature, humidity, and corrosion in the working environment.
Specifically, the commonly used wire materials in electronic harnesses include the following:
Copper wire: Copper wire has good conductivity and mechanical properties, and is the most commonly used wire material in electronic harnesses.
Aluminum wire: Aluminum wire has lower conductivity than copper wire, but is lighter in weight and lower in cost.
Tin plated copper wire: Tin plated copper wire has good conductivity and oxidation resistance, suitable for humid environments.
Shielded wire: Shielded wire has good anti-interference ability and is suitable for transmitting high-frequency signals in circuits.
In practical applications, appropriate wire materials should be selected based on the specific usage environment and requirements of the wiring harness.
2、 Analysis of common wire faults
There are several types of electronic harness faults:
Electrical fault: Electrical fault refers to the abnormal conductivity of the wiring harness, causing the circuit to malfunction. The main causes of electrical faults are as follows:
Wire breakage: Wire breakage is the most common type of electrical fault.
Short circuit of wire: A short circuit of wire can cause overcurrent in the circuit, burning out the circuit or components.
Wire leakage: Wire leakage can lead to a decrease in circuit performance and even cause safety hazards.
Mechanical failure: Mechanical failure refers to damage to the physical structure of the wiring harness, causing it to malfunction. The main causes of mechanical failures are as follows:
Wire tensile fracture: Wire tensile fracture is the most common type of mechanical failure.
Bending deformation of wire: Bending deformation of wire can lead to a decrease in its conductivity.
Wire cut: Cutting the wire can cause a broken wire harness.
Environmental fault: Environmental fault refers to the inability of the wiring harness to function properly due to corrosion, aging, and other factors in the working environment. The main causes of environmental failures are as follows:
Oxidative corrosion: Wire is prone to oxidative corrosion in humid environments.
High temperature aging: Wire is prone to aging in high temperature environments, leading to a decrease in its conductivity.
UV irradiation: The wire is prone to aging under UV irradiation, resulting in a decrease in the insulation performance of the wire.
3、 How to avoid wire faults
To avoid wire failures, the following measures should be taken:
Choose appropriate wire materials: Choose the appropriate wire materials based on the specific usage environment and requirements of the wiring harness.
Proper use of wiring harnesses: When using wiring harnesses, attention should be paid to avoiding mechanical damage such as stretching, bending, and cutting, as well as avoiding environmental impacts such as corrosion and aging.
Regular maintenance of wiring harnesses: Regularly inspect the wiring harnesses and promptly handle any abnormalities found.
Through the above measures, the probability of wire failure can be effectively reduced, ensuring the normal operation of electronic products.
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