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• Automotive wiring harnesses are functionally divided into two types: power lines, which carry electricity to drive the actuator (actuator), and signal lines, which carry sensor input commands. Power lines are thick wires that carry large currents, while signal lines are thin wires that do not carry electricity (optical fiber communication); for example, the cross-sectional area of wires used for signal circuits is 0.3, 0.5mm2.

• In the motor, executive components with wire cross-sectional area of 0.85, 1.25mm2, while the power circuit with wire cross-sectional area of 2, 3, 5mm2; and special circuits (starter, alternator, engine ground wire, etc.) are 8, 10, 15, 20mm2 different specifications. The larger the cross-sectional area of the conductor, the greater the current capacity. The choice of wire, in addition to the consideration of electrical performance, but also by the physical properties of the car when the constraints, so its choice of a wide range. For example, the wire between the frequently opened/closed doors and across the body of a rental car should be composed of wire with good flexural properties. Wires used in areas with high temperatures are generally made of vinyl chloride and polyethylene covered wires with good insulation and heat resistance. In recent years, the use of electromagnetic shielding wires for weak signal circuits has also increased.

• With the increase in the functions of the car, the widespread application of electronic control technology, more and more electrical parts, wires will also be more and more, the number of circuits on the car and the power consumption increased significantly, the wiring harness also becomes thicker and heavier. This is a big problem that needs to be solved, how to make a large number of wire harnesses in the limited space of the car how to more effectively and reasonably arranged, so that the car wiring harness to play a greater function, has become a problem facing the automotive manufacturing industry.

• Before arranging the wiring harness, a wiring harness diagram is drawn. It does not reflect how the electrical parts are connected to each other and is not affected by the size and shape of the electrical components or the distance between them. A wiring harness diagram, on the other hand, must take into account the size and shape of each electrical component and the distance between them, and must reflect how the electrical parts are connected to each other.

• The wiring harness factory technician according to the wiring harness diagram into the harness line board, workers will be in accordance with the provisions of the line board to cut the wire line. The main wiring harness is generally divided into engine (ignition, EFI, power generation, starter), instrumentation, lighting, air conditioning, auxiliary appliances and other parts, with the main harness and branch harness. A whole car main harness has several branch harnesses, just like a tree pole and tree branches. The main wiring harness of the whole car often takes the instrument panel as the core part and extends back and forth. For reasons such as length or ease of assembly, the wiring harnesses of some cars are divided into front-end harnesses (including instrumentation, engine, front light assembly, air conditioning, battery), rear-end harnesses (taillight assembly, license plate light, trunk light), roof harnesses (doors, roof lights, audio speakers), etc. Each end of the harness will be marked with a number and letter to indicate the object of the wire connection, the operator sees the mark can be correctly connected to the corresponding wires and electrical devices, which is particularly useful when repairing or replacing the harness. At the same time, the color of the wire is divided into single-color wire and two-color wire, the use of color is also specified, generally the standard set by the car manufacturers themselves. Our industry standards only provide for the main color, such as the provisions of the single black dedicated to the hitch line, red monochrome for power lines, not to be confused.

• Wiring harness with woven wire or plastic tape wrapping, for safety, processing and maintenance convenience, woven wire wrapping has been eliminated, is now wrapped with sticky plastic tape. The connection between the harness and the harness, between the harness and the electrical parts, using a joint plug-in or wire lugs. Coupling plug-in made of plastic, divided into a plug and socket. The connection between the harness and the harness is connected with the coupling plug, and the connection between the harness and the electrical parts is connected with the coupling plug or the wire lug.