1. Background:
Wheel wire harnesses in automobiles consist of a variety of materials, including ABS cable sheaths, EPB cable sheaths, twisted pairs, single-core wires, protective tubes, rubber parts, injection molded parts, terminals, rain plugs, connectors, and tapes. Challenges arise when the design software cannot identify potential crease problems from different wire harness directions, and protective tube manufacturers lack clear bending radius recommendations.
2. Case Background:
Upon the installation of the wheel harness on a specific vehicle model, surface creases were observed. Interestingly, when the harness was stationary and horizontal, no creases were visible. However, once installed on the car chassis, creases manifested.
3. Cause Analysis:
– 3.1 Protective Tube Filling:
– *Issue:* Insufficient filling in the protective tube leading to easy bending and creasing.
– *Solution:* Adjust protective tube dimensions to increase filling rate.
– 3.2 Wire Harness Twist:
– *Issue:* Twisting during processing or unreasonable wiring design causing deformation.
– *Solution:* Ensure flat placement during processing and redesign molds if necessary.
– 3.3 Unreasonable Design:
– *Issue:* Redundant size or small bending radius in the wheel harness movement area.
– *Solution:* Optimize wiring design for sufficient size and bending radius.
4. Effect Verification:
– 4.1 Static Verification:
– Increased protective tube filling to over 70%, eliminating creases.
– 4.2 Dynamic Verification:
– Creases observed after enhanced bad-road durability test. Further optimization required.
5. Optimization of Wheel Harness Distribution:
Evaluate and experimentally verify layout changes to meet wheel jump test requirements. Consider round jumping experimental conditions and judgment criteria for the wheel jump test.
This comprehensive analysis identifies the root causes of creases in wheel harnesses and proposes initial solutions. In the next part, we will delve into the measures taken for improvement and the overall impact on wheel harness life.