Research On Reliability Design Of Automotive Harness And Connector Selection Analysis

With the rapid development of new automotive technology such as electrification and intellectualization,electronic and electrical components in the vehicle increases rapidly.Modern automotive has been developed rapidly from simple circuits and mechanical structure into integration of electromechanical.The purpose of wiring harness design is to improve the service life of vehicle electronic and electrical system to more effectively protect the safety of vehicles and passengers.If the design method is improper,it will result in shorting circuit,even endanger the safety of vehicles and passengers.therefore,the stable and reliable design method of automotive wiring harness is an important guarantee to realize the design purpose.The main method to improve the reliability of automotive wiring harness is to reduce the complexity of automotive wiring harness design by using as fewer circuits as possible to connect all electronic and electrical components.The communication characteristics of CAN bus based on multiplex interconnection technology is discussed for the reliability design and selection of automotive connectors and the reliability design of automotive wiring harness.In the wiring harness system,the traditional point-to-point design method has been proven not to satisfy the complex electronic and electrical circuits in modern cars.Therefore,CAN bus technology based on the multiplex interconnection technology has been widely introduced into automotive wiring harness design.The reliability design of automotive wiring harness is discussed after studying the topology and communication characteristics on CAN bus.As the key component of the automotive wiring harness,correct selection on the automotive connector can significantly increase the reliability of the whole automotive wiring harness system.From the engineering view,use electrical contact theory to analyze the key factors effecting the reliability of the connector terminals and use the design of experiment method to verify the influence on every key mechanical dimension.Besides,discuss the importance of the connector terminal plating and the relevant usage requirements.From the application view,according to the engineering experience,depending on the automotive connector design temperature level,vibration level,waterproof level and so on,summary the automotive connector usage in the vehicle and improve the automotive connector selection process as well.As to the reliability design of automotive wiring harness system,introduce the forward engineering design to illustrate the relevant design process and method,discussing the set up of the automotive wiring haress logical shcematic,the design pricinples of physical schematica and basic rules on the 3D topology.In order to improve the reliability of automotive wiring harness,the potential failure modules and their causes are analyzed and studied according to the automotive wiring harness manufacturing and performance requirements.In addition to the automotive connectors,automotive wiring harness also involves a lot of accessories such as eyelet,retainer,tie,shield,wire and so on.With the engineering experience,the detailed application method is discussed according to their characteristics.In the automotive connector,it is pointed out that material,mechanical structure,terminal plating are the important factors and the improved automotive connector selection process can reduce the issue on the automotive connector selection.In the research on the selection on automotive wiring harness accessories,it is proven that the correct selection plays an important role in the reliability design of automotive wiring harness.In the reliability design of automotive wiring harness system,the methods and notes are discussed in detail for every step,which can reduce the complexity of automotive wiring harness design and improve the reliability design,too.Through the research above,it's proven that it can effectively improve the safety and reliability of automotive wiring harness system,shorten the design time on the automotive connectors and wiring harness,generate significant social and economic benefits.