Several types of failures of automotive wiring harnesses

The wiring harness is mainly composed of wires, terminals, connectors, packaging, nails, slots, etc. Due to the composition of irregular parts, the manufacturing of wiring harnesses is a labor-intensive industry with low automation. Many manual operations affect the standardization of wiring harnesses, and the failure in the manufacturing process of wiring harnesses is a random and uncontrollable failure mode.

1. Automobile assembly failure.
The wiring harness is arranged on the actual vehicle, and the wiring harness will be dispersed into multiple parts, thereby improving the assembly type and maintainability. But at the same time, the increase in wiring harness interfaces and positioning parts means that the possibility of failure increases. This section classifies and summarizes the failure cases that occur in the assembly of the whole vehicle to improve the reliability of wiring harness assembly.

2. Fixed failure.
It refers to the detachment of the positioning parts of the wiring harness itself at the fixing hole or tie. This failure does not affect the function or the use of the whole vehicle.
Functional failure is a serious failure mode, which will lead to the loss of a certain function of the whole vehicle, seriously affecting the driving of the vehicle and the safety of the driver.

3. Appearance failure.
It is a form of failure that affects customer perception. Most of the wiring harnesses are arranged in areas that are not suitable for customers to perceive, but the process or space of the wiring harness supplier will affect the assembly of parts attached to the wiring harness, resulting in matching or aesthetic problems.

Such problems should be considered in the early design whether the wiring harness or the plug-in motion envelope area has the risk of interference with the surrounding parts, so as to choose the appropriate position to arrange the fixed points to ensure that the function is met and the appearance is beautiful.

4. Durability failure.
Durability failure is a failure mode formed in the middle link with the use of the vehicle. It occurs randomly with the life cycle of the vehicle and has unpredictable performance. Once it fails, it will cause great complaints from customers about the brand. This kind of failure often occurs in the envelope area of ​​the moving parts, and it occurs after a certain wear and tear, which is difficult to detect in the early stage.