Estimation method of wire diameter of automobile wiring harness
When using the CATIA module for wire harness data production, the wire harness segment diameter is written into the software as an important parameter. All subsequent clearance checks and motion analysis are based on this value. Therefore, if there is a big difference from the actual situation, it will inevitably lead to the original requirement of meeting the safety gap, and it will be found to have interfered when the vehicle is actually installed, or even cannot be assembled. Here provides a theoretical calculation method for estimating the outer diameter of automobile wiring harness (wire harness standard algorithm). A wire harness segment is a collection that binds all wires together with tape or other wrapping. Taking into account that the tape is only wound on the wire harness, and the wrapping of casings such as corrugated pipes also needs to determine the outer diameter of the wire harness before selection. Therefore, when calculating, we first put down this part of the dressing. In this case, the cross-sectional area of the harness segment is equal to the sum of the cross-sectional areas of all wires. Therefore:
In the formula, S represents the cross-sectional area of the harness section, and Si represents the cross-sectional area of the i-th wire;
We set the cross section of the wire harness segment to be a circle by default, then there is, where D is the diameter of the wire harness segment, and Pi is the pi.
The insulation wall of the German standard wire is thinner than that of the Japanese standard wire. With the increasing number of vehicle electrical components, German standard wires are being used more and more. Here we also select examples of German marking lines for related explanations.
Table 1 German standard wire parameter table
It is worth mentioning that, generally speaking of 0.5 wire, 0.5 only refers to the cross-sectional area of all copper wires, and does not include the cross-sectional area of the insulation around the wire. Therefore, the maximum outer diameter is the parameter value we want when calculating.
example:
Through the definition of related principles, we have known that a section of wire harness consists of 4 0.5 wires, 3 1.5 wires, and 2 0.35 wires. Find the outer diameter of this section of wire harness. Then we can find by formula 1: S=2x3.1416x(1.4/2)2 +4x3.1416x(1.6/2)2 +3x3.1416x(2.4/2)2 =24.693 D=5.61 obtained by formula 2 ). If this section of line is defined to be wrapped with tape and the tape thickness is 0.14, the diameter of the wire bundle end is D=5.6+0.14x2=5.88, which is an integer of 6mm.
2) If this section of line defines that the tape is tightly wound and the tape thickness is 0.14, then the maximum diameter of the wire harness section is D=5.6+0.14x2x2=6.16mm, which is an integer of 6mm.
3) If this section of line defines corrugated tube wrapping, according to the outer diameter of the wire harness section 5.6mm, a corrugated tube with an inner diameter of 7mm can be selected. If the outer diameter of the bellows is 10mm, the outer diameter of the wire harness section is considered to be 10mm.
Harness data designers can suggest related Excel tables with calculation formulas, or based on actual work experience or measurements. Establish a statistical table of the cross-sectional outer diameters of the various branches of the relevant harness breaks of the typical models, so that the outer diameter of the harness can be estimated quickly and conveniently.
In the formula, S represents the cross-sectional area of the harness section, and Si represents the cross-sectional area of the i-th wire;
We set the cross section of the wire harness segment to be a circle by default, then there is, where D is the diameter of the wire harness segment, and Pi is the pi.
The insulation wall of the German standard wire is thinner than that of the Japanese standard wire. With the increasing number of vehicle electrical components, German standard wires are being used more and more. Here we also select examples of German marking lines for related explanations.
Table 1 German standard wire parameter table
It is worth mentioning that, generally speaking of 0.5 wire, 0.5 only refers to the cross-sectional area of all copper wires, and does not include the cross-sectional area of the insulation around the wire. Therefore, the maximum outer diameter is the parameter value we want when calculating.
example:
Through the definition of related principles, we have known that a section of wire harness consists of 4 0.5 wires, 3 1.5 wires, and 2 0.35 wires. Find the outer diameter of this section of wire harness. Then we can find by formula 1: S=2x3.1416x(1.4/2)2 +4x3.1416x(1.6/2)2 +3x3.1416x(2.4/2)2 =24.693 D=5.61 obtained by formula 2 ). If this section of line is defined to be wrapped with tape and the tape thickness is 0.14, the diameter of the wire bundle end is D=5.6+0.14x2=5.88, which is an integer of 6mm.
2) If this section of line defines that the tape is tightly wound and the tape thickness is 0.14, then the maximum diameter of the wire harness section is D=5.6+0.14x2x2=6.16mm, which is an integer of 6mm.
3) If this section of line defines corrugated tube wrapping, according to the outer diameter of the wire harness section 5.6mm, a corrugated tube with an inner diameter of 7mm can be selected. If the outer diameter of the bellows is 10mm, the outer diameter of the wire harness section is considered to be 10mm.
Harness data designers can suggest related Excel tables with calculation formulas, or based on actual work experience or measurements. Establish a statistical table of the cross-sectional outer diameters of the various branches of the relevant harness breaks of the typical models, so that the outer diameter of the harness can be estimated quickly and conveniently.
