Common materials for automotive wiring harness seals

The car wiring harness is known as the “vessel” of a car and is generally considered to be the central nervous system of a car, which connects the on-board computer with various related functions on the vehicle. Whether the manufacturing technology of automotive wiring harness is advanced is an important aspect that affects the performance of automobiles.

Those who are engaged in auto wire seal processing know that the wiring harness of the automobile is generally made of a seal (also called a rubber piece) for the purpose of wearing, waterproofing, sealing, etc. The design of the automobile wire harness seal is for the overall performance of the automobile wire harness. The impact is very large, and there are many difficulties in the design. It is mainly distributed in the following parts: the interface between the engine and the cab, the interface between the front compartment and the cab (two in the left and right), the four-door (or the back door) and the compartment interface. , the entrance to the fuel tank. There are three common materials for automotive wire harness seals:

One, neoprene. Its characteristics are good resistance to ozone, heat aging, oil resistance, etc., and it is flame retardant and self-extinguishing; but its low temperature resistance is not good.

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Second, natural rubber. The characteristics of the wire harness material are good elasticity and mechanical strength, excellent flex resistance, high tear strength and good cold resistance. Disadvantages: The aging resistance is not good, it is not resistant to oil and ozone, and it is flammable.

Third, silicone rubber. Heat resistance, cold resistance and weather resistance of the Silicone Wire Seal are good; the disadvantage is that it is not resistant to oil. The characteristics of EPDM: weather resistance, ozone resistance, heat resistance, corrosion resistance, acid and alkali resistance, etc., and high strength and high expansion ratio; Disadvantages: poor adhesion, and no natural elasticity Good rubber and poor oil resistance.

Four, EPDM. It is also the most important common material for automobile wire seal. Many automotive wire harness seals use it, which has good comprehensive performance and strong adaptability.

At present, the automobile system is getting bigger and bigger, and the market competition is becoming more and more fierce. Many automobile companies are increasing the technology content to reduce costs and maintain their competitive advantage and market share. However, safety is always the starting point of all R&D work. When designing a R&D team, it must still follow certain design principles in order to maintain its competitive advantage while maintaining quality and quantity.

Production process of automobile wiring harness is briefly introduced by Automobile Wire Seal Manufacturer.

When cars no longer appear in people’s vision as luxury goods, car sales begin to rise rapidly, and the market of automobile wiring harnesses gradually expands. More and more wiring harnesses processing manufacturers pay attention to the processing and production process of automobile wiring harnesses, and improve and mature the processing and production technology of automobile wiring harnesses. The standard and reliability of automobile wiring harness directly affect the service life and safety performance of automobile. Automobile wire harness processing production is generally by wire, contact terminal (connector) and sheath and other parts processing combination, here oushida automobile harness factory for you to introduce the automobile wire harness processing production process and technology.

Crimping process: the crimping of automobile wiring harness at the terminals shall be carried out in strict accordance with the operating instructions. Some wiring harnesses will be covered with waterproof plug and then crimping, and some need to be covered with protective cover and then crimping after returning from the pre-installed station. These stations need random inspection and supervision at any time, automobile wiring harness process general wiring harness production process is more strict, strict quality requirements is the basis of the enterprise for a long time.

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Cutting line technology: the complete step should be that the storekeeper issues the materials according to the material requester and leads the production department to cut the corrugated pipe, PVC pipe and fiberglass pipe. The cut section should be complete, but this cutting process can also be called to the supplier. Third, cut and strip the car wire, the opening requirements and length should not have any deviation, the length is generally set in the display panel, the opening personnel need to monitor at any time, the length, cutting line incision, stripping length to check. The opening process directly affects the subsequent production process of automobile wiring harness and relates to the whole progress.

Preassembly process: the delivery date and quality assurance of automobile wiring harness Automotive connector Seal processing largely depend on the setting of preassembly station. The rationality of preassembly process directly affects the efficiency of wiring harness assembly and reflects the professional technology of r&d personnel. It requires engineers to summarize and optimize the pre-installation position of automobile wiring harness on site at any time. Many automobile wiring harness manufacturers have also made many attempts to optimize and make progress in assembly. Avoid excessive workload at a certain station and small workload at other stations, or the person in charge should constantly summarize experience on the site.

Final assembly process: according to the assembly board designed by r&d department, design tooling equipment, imported electronic components, material box specifications and sizes, and paste all assembly jackets and nearby Numbers on material box to improve assembly efficiency. The assembly content and requirements should be set for each tooling position to prevent the excessive workload of each station from affecting the progress of the entire assembly line.

Automobile wiring harness processing directly affects the use and safety of automobiles, automobile manufacturers should pay attention to the selection of automobile wiring harness factories, and have a certain understanding of automobile wiring harness processing and production.

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What are the requirements for wire harness processing?

We usually see the wire harness is finished products, but in the process of wire harness processing production, the requirements on the wire harness is very strict, so how strict? The following Wire Seal Supplier to introduce to you:

What are the requirements for wire harness processing?

1. After the terminal is pressed, the rubber shell should be worn. This step cannot be automated but can only be done manually.

2. After the wiring harness is completely made, the quality department shall conduct full inspection, and the unqualified products shall be reworked if they are not in place.

3. The incoming materials should be correct, the raw materials should be inspected, and production scrap should be eliminated from the source.

4. For other complicated wiring harnesses, casing piercing and thermal shrinkage may be required.

5. After confirming the materials, cutting lines and terminals are required. The first piece needs to be completed.

Above, is the quality assurance process in the wiring harness processing process, each step needs to be careful, to avoid unqualified wiring harness into the next program, said so much, do you have a better understanding of it?

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Basic process of wire harness production:

1. Acceptance link: wiring harness manufacturers said that the main is an acceptance of incoming materials, can use ROHS instrument or other instruments for basic testing, the main acceptance of harmful substances is lead, mercury, cadmium, brominated biphenyl polybrominated diphenyl ether, etc..

2. Will test the qualified wire on the wire rack, wire feeding, you should pay attention to avoid scratching the surface of the wire.

3. Cutting line; At this time to use the wire cutting machine to cut the wire into the required length.

4. Peeling: according to SOP, insulation skin shall be carried out, mainly using pneumatic peeling machine

5. Twisted wire: finish and twist the conductor at the joint. The main is the use of twisting machine.

6. Riveting: use the terminal machine to rivet the conductor and plug terminals at the junction.

7. Seven, assembly: to handle the wiring harness assembly, mainly assembly of plastic plug shell.

8. Test. The final test of the product can only be conducted after passing the test.

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How do you tell if the wiring harness is burned out?

Wiring harnesses need to be replaced if the following symptoms occur:

Wiring harness processing _ wiring harness burning out the rule is: in the power system circuit, where the iron, the wiring harness is burned, burned and intact parts junction, can be considered to be the wiring harness, such as wiring harness burning bad to the wiring part of an electrical equipment, indicating that the electrical equipment failure.

1) battery line is burnt out

(1) if the battery line only burned part, then check and cable burned out in contact with the parts, after cleaning burr replacement battery line.

(2) such as the battery line all burned out, that starter failure. Connect the test lamp in the starter electromagnetic switch + pole and the positive pole of the battery. If the test lamp does not work, it indicates that the starter internal failure.

2) if the wiring harness between the generator + pole and the terminal post of the starter battery burns out and stops the generator, remove and release the lead wire of the motor + pole, connect a power cord between the battery + pole, and the other end contacts the generator + pole. If sparks occur, the generator fails; if no sparks occur, the wiring harness fails.

3) wiring harness and relay leads are burnt out

(1) turn off the power switch, remove the relay, let it hang in the air, between the relay shell and the body access test lamp, such as the light, that the relay fault; If the light does not work, proceed to the following steps.

(2) turn on the power switch, if the test lamp does not work, that the relay is trouble-free, only replace the wiring harness, if the test lamp shows that the relay is faulty, the relay should be replaced.

That’s all for the sharing, thanks for your reading, and we also supply automobile wire seal, automotive wire harness seals for sale, if you have any demand for our products, just feel free to contact us.

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Design considerations for seals shared by 4 pin Automobile Connector Seal supplier.

1. Please read the instructions of each series of products by yourself before designing the groove, and make it clear that the product USES integral groove or split groove; Attention should be paid to avoid sharp edges in the process of sealing parts installation. The hole must be loaded into the overall groove with sealing parts by means of installation tools. Designers should consider the groove size accuracy, surface roughness, extrusion clearance and other parameters, please refer to the product instructions, drawings and dimensions.

2. Before installing the seals, it is necessary to ensure that there are no impurities or cracks in the sealing groove. Gradually install seals in sequence; Avoid sharp edge during installation, and hold the sealing element upright to avoid distortion and skew. If the split groove, finally tighten the gland.

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Several major factors affecting the sealing performance shared by Connector Cavity Plug Supplier.

1. Speed

When the motion speed is very low (< 0.03m/s), the smoothness of the operation of the equipment and whether there is “crawling” phenomenon should be considered. When the movement speed is very high (>, 0.8m/s), the lubricating oil film may be damaged, and the seal may be heated due to friction due to poor lubrication, resulting in a greatly reduced service life.

It is recommended that polyurethane or rubber seal should work within the speed range of 0.03m/s ~ 0.8m/s.

2. The temperature

Low temperature will make polyurethane or rubber seal elasticity reduced, resulting in leakage, and even the whole seal becomes hard and brittle. High temperature will make the oil seal volume expansion, soft, resulting in rapid increase in the friction resistance and pressure resistance capacity. It is suggested that the continuous operating temperature range of polyurethane or rubber seal is -10℃ ~ +80℃.

3. Work stress

The seal has a zui minimum service pressure requirement. Low pressure work must choose low friction performance, starting resistance small seals. Below 2.5mpa, polyurethane seals are not suitable; High pressure to consider the pressure deformation of seals, need to prevent extrusion ring, groove processing also has special requirements.

In addition, different materials of seals have different zui good working pressure range. For polyurethane seals, the working pressure range of zui jia is 2.5 ~ 31.5MPa.

The influence of temperature and pressure on the sealing performance is interrelated, so it should be considered comprehensively. See table:

Imported polyurethane PU material

Maximum working pressure

Maximum temperature range

The velocity is -25 ~ +80 ~ 25 ~ +110

0.5 m/s 28 mpa 25 mpa

0.15 m/s 40 mpa 35 mpa

4. Working medium

In addition to selecting working media strictly according to the manufacturer’s recommendations, it is essential to keep working media clean. The aging or contamination of oil will not only make the components in the system malfunction, accelerate the aging and wear of seals, but also the dirt in the system may scratch or embed in the seals, making the seals invalid. Therefore, it is necessary to check the oil quality and cleanliness regularly, and replace the oil filter or oil according to the maintenance specifications of the equipment. The residual air in the oil cylinder after high pressure compression will produce high temperature oil seal burning, even carbonization. In order to avoid this situation, the initial operation of the hydraulic system, should be exhaust treatment. The hydraulic cylinder should also run at a low pressure and slow speed for several minutes to confirm that the residual air in the oil has been discharged before it can work normally.

5. Lateral load

The supporting ring must be installed on the piston to ensure that the cylinder can bear larger load. The sealing element and the supporting ring have completely different functions, and the sealing element cannot replace the supporting ring load. The hydraulic cylinder with lateral force must be equipped with support ring with strong bearing capacity (metal ring can be used for heavy load) to prevent leakage and abnormal wear caused by eccentric working of sealing element.

6. Hydraulic shock

There are many factors that produce hydraulic impact, such as the moment when the bucket of an excavator suddenly hits a stone, or when the crane lifts or drops heavy objects. Except in the factor, for high pressure large flow hydraulic system, the executive element (hydraulic cylinder or hydraulic motor, etc.) when reversing, if the performance of the reversing valve is not very good, it is easy to produce hydraulic impact. The instantaneous high pressure produced by hydraulic shock may be several times the working pressure of the system, which in a very short time will tear the oil seal or partially squeeze it into the gap, causing serious damage. The general hydraulic impact of the cylinder should be installed on the piston rod buffer ring and baffle ring. The buffer ring is mounted in front of the oil seal to absorb most of the impact pressure, and the retaining ring prevents the oil seal from squeezing into the gap under high pressure and causing the root to be bitten.

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