Wire harnesses for automotive electrical equipment
Wire harnesses
DESIGNATION
Wire harnesses are designed for connection of electrical networks of motor-and-tractor equipment. Harnesses are mounted on the following machinery: cars, buses, tractors, automobile and tractor trailers and semitrailers, agricultural machines, road machines, motorcycles, lift trucks, auto cranes.
ARRANGEMENT
Harnesses consist of armored or unarmored wires joint together and attached to other elements (coupling devices, ends, etc.).
Harnesses may consist of motor-and-tractor wires; railway vehicle wires; on-board network wires; mounting wires; АМГ wires. Instead of wires it is possible to apply multi-core cables, including helical conductors.
Wires are armored with terminals for motor-and-tractor low-voltage cables without soldering or with subsequent soldering, plug connectors. Places of connection of wire to connector are protected according to design documents.
According to design documents' requirements, wire ends not armored with connectors are tinned with ПОС-61 solder.
Wires are joint together with winding, PVC tape with separator, cable tie, PVC tube, corrugated tube, cotton braiding etc. in case when radio-frequency interference suppression is required, wires are joint into harness and shielded with copper wire winding or braiding.
Requirements to electrical parameters:
- direct-current electrical resistance of conductors for a length of 1 km at a temperature of +20°С complies with GOST 22483;
- voltage drop at the terminal connection with the wire is not more than 20 mV,
Voltage drop at the terminal connection with the wire, armored by cold pressing method, shall be not less than specified in the table below:
|
Rated wire area, mm² |
Rated testing current, А |
Voltage drop, mV |
|
0,20 |
5 |
30 |
|
0,35 |
5 |
30 |
|
0,50 |
5 |
30 |
|
0,75 |
10 |
30 |
|
1,0 |
10 |
20 |
|
1,2 |
10 |
15 |
|
1,5 |
15 |
30 |
|
2,0 |
20 |
15 |
|
2,5 |
30 |
20 |
|
3,0 |
30 |
15 |
|
4,0 |
50 |
30 |
|
5,0 |
50 |
25 |
|
6,0 |
50 |
20 |
Requirements to mechanical parameters:
- force of terminal pullout from the wire shall be not less than specified in the table below:
|
Rated wire area, mm² |
Pullout force, N |
||||||
|
For plug connectors of series: |
For bolted connectors |
||||||
|
2.8 |
4.8 |
6.35 |
7.7 |
9.5 |
|
||
|
0.20 |
- |
19.6 |
- |
- |
- |
19.6 |
|
|
0.35 |
39.2 |
24.5 |
58.3 |
- |
- |
39.2 |
|
|
0.50 |
58.9 |
58.9 |
78.5 |
78.5 |
- |
78.5 |
|
|
0.75 |
68.7 |
68.7 |
78.5 |
78.5 |
- |
78.5 |
|
|
1.0 |
78.5 |
78.5 |
137.3 |
137.3 |
- |
137.3 |
|
|
1.2 |
88.3 |
88.3 |
137.3 |
137.3 |
- |
137.3 |
|
|
1.5 |
98.1 |
98.1 |
137.3 |
137.3 |
- |
137.3 |
|
|
2.0 |
- |
- |
137.3 |
137.3 |
- |
137.3 |
|
|
2.5 |
- |
- |
137.3 |
137.3 |
- |
137.3 |
|
|
3.0 |
- |
- |
196.2 |
196.2 |
- |
137.3 |
|
|
4.0 |
- |
- |
294.3 |
294.3 |
294.3 |
294.3 |
|
|
5.0 |
- |
- |
343.4 |
343.4 |
343.4 |
294.3 |
|
|
6.0 |
- |
- |
441.5 |
441.5 |
441.5 |
441.5 |
|
Requirements to resistance to external influencing factors:
- harnesses are resistant to the effect of low ambient temperature of -40°С.
- harnesses are resistant to the effect of high ambient temperature of +70°С.
- harnesses are resistant to the continuous effect of high atmospheric humidity up to 98% at ambient temperature of +40°C.
- harnesses are resistant to the effect of mineral oil, gasoline, diesel fuel, water and their vapors.
Harnesses do not spread combustion when single laid.
Minimal operating time:
9000 hours for harnesses of high category;
3000 hours for harnesses of 1st category laid in engine rooms;
5000 hours for other harnesses.
Harnesses are designed for operation at ambient temperatures:
- from -40˚С to +80˚С - for harnesses mounted in engine rooms and on engines;
- from -40˚С to +70˚С - for harnesses mounted in cabs or enclosed bodies as well as outside a vehicle;
- from -60˚С to +70˚С - for harnesses of ХЛ modification.
Operational life of harnesses is not less than 10 years.
Regulations: GOST 23544-84