Specific measures to prevent errors in wiring harness design for new energy vehicles

With the continuous progress and development of the market economy, the automobile industry has gradually entered people's field of vision. With the continuous improvement of people's living standards, the sales of automobiles are also increasing. In this way, the automobile parts industry will continue to rise with the development of automobile sales. In order to better respond to the country's call for energy conservation and emission reduction, automobile companies are also constantly improving the promotion of new energy vehicles, converting the power source of automobiles into electrical energy, so that automobile production can be better developed. This article mainly analyzes the development status of new energy vehicles, and then studies and discusses the error-proofing technology of wiring harness design connectors.

In recent years, the rapid development of the domestic automobile industry has provided favorable opportunities for the design and development of the automotive parts industry, and has also placed higher and higher requirements on the quality of parts. When we design and manufacture new energy vehicles, we need to pay attention to the design of physical error prevention. The physical error prevention of automotive connectors needs to start from the source and the root of the problem, better identify the error prevention position, reduce the potential risks of product misinstallation, missing installation and mixed installation, thereby reducing production costs and better improving product quality, enhancing product competitiveness in the market, and allowing new energy vehicles to develop better in the market.

New energy vehicle wiring harness design

Basic Overview of Error Proofing Technology

The continuous development of the domestic automobile industry and the continuous increase in automobile sales have also provided a favorable opportunity for the development of new energy vehicles. Under the guidance of the market environment, new energy vehicles are also inevitable for economic development. With the increase in the number of automobiles, related industries have also developed greatly, among which the automobile parts industry has developed more rapidly and is an important challenge for the development of the automobile industry. The automobile wiring harness is a basic component of automobile parts. It is composed of a variety of connectors. During the assembly process, its quality must be accurately grasped because they will have a direct impact on the quality and performance of the car. In this situation, it is also necessary to pay attention to the possible errors in design and manufacturing, and to fundamentally solve the problem reasonably. When processing the automobile wiring harness, it is necessary to pay attention to the setting of the error-proofing position, and use the error-proofing design to effectively avoid some unnecessary risks, minimize the defective problems of the product, thereby achieving the improvement of the quality of automobile parts products and improving its market competitiveness. With the application of error-proofing technology of wiring harness design connectors, it can play an important role in many aspects. In addition, when making error-proofing settings, it is also necessary to pay attention to its cost control, so as to be fully prepared for the development of design work.

Generally speaking, the main significance of error-proofing technology is that it can bring better product experience to users and not provide customers with defective products; it is also helpful to improve the quality of the product itself and reduce the number of waste products; it can also effectively reduce the cost of the manufacturing process and reduce the waste that may occur in manufacturing production. In general, in the design of automotive wiring harnesses, connector error-proofing methods can be mainly divided into several types, namely: other error-proofing, color error-proofing, structural error-proofing, size error-proofing, component error-proofing, and docking error-proofing.

Specific measures for wiring harness error prevention

1. Error prevention from a structural perspective

When designing automotive wiring harnesses, some identical connectors are usually found in adjacent positions. This approach is mainly to use the electrical ends to select connectors that fit each other, so as to achieve the purpose of error prevention. In addition, this error prevention method also has a very positive effect on the entire product development process, which can effectively highlight the main role of the structure and ensure the formation of the project. If you want to prevent errors in the structure, you need to refer to different electrical ends in the early stage of design, and then choose different connectors, so as to minimize the restrictions on connector connection ends and mold types.

2. Error proofing from the components

In the process of manufacturing automotive wiring harnesses, the type of connector must be freely selected. Generally speaking, there are the following options: First, the satisfaction of the electrical end is taken as the main basis. When making a selection, attention should be paid to the appearance of the connector. At the same time, the matching end should be kept unchanged, and its shape and length should be reasonably changed. The purpose of misplacement can be achieved by changing the appearance; second, in the manufacturing process, attention should be paid to the differences between different connectors. The connector itself does not change in the design. It is necessary to freely select the back cover and lock of the connector, and set anti-error points on the guide groove. In this way, the manufacturing quality of the product can be effectively guaranteed.

3. Make sure you make mistakes in color

There are many error prevention methods in the process of wiring harness design. One of the more effective methods is color error prevention. This error prevention method can more intuitively show the problems in the design process. The color error prevention method can make people more clear at a glance, and its biggest advantage is its clarity. In the process of design, it is often necessary to comprehensively consider the limitations of connector components, but it is impossible to achieve the purpose of error prevention. Therefore, it is necessary to pay attention to color error prevention. The purpose of error prevention can be achieved by selecting connectors of different colors, thereby paving the way for the development of connector work.

4. Error proofing from the perspective of size

Size error prevention is more suitable for application in locations where error prevention is prone to occur. Generally, when the functions of various connectors are relatively similar, it is necessary to determine the orientation of fixed components by finding different ways of wire-outlet protection lines, so as to achieve the ultimate goal of size error prevention. In the manufacturing process, the most scientific and reasonable size error prevention is to pay attention to the connector end, to achieve plug-in, and at the same time to ensure its uniqueness and accuracy. For example, when performing size error prevention on the two connectors AB, it should be noted that although the two connectors are not essentially different, they must be plugged in through size error prevention, so that connector A can be plugged in with the A electrical end, and connector B can be plugged in with electrical end B, thereby improving the uniqueness and accuracy of the connector connection.

5. Error prevention from docking

When designing automotive wiring harnesses, one of the more common situations is that problems occur during docking. In this case, it is generally impossible to perform color or appearance error prevention. In this case, the connector needs to use certain measures when docking to effectively avoid problems such as missed insertion and wrong insertion that are easy to occur in the design, thereby providing a better foundation for the docking of the connector. For docking error prevention, the main thing is to swap the male and female connectors at the docking end to allow the entire error prevention function in the design to be brought into play. In order to better play the docking error prevention design, it is necessary to fully consider the docking error prevention in the design under the conditions of board-side electrical appliances or multiple groups of docking.

6. Other error prevention

In the process of designing the automotive wiring harness, in addition to the above-mentioned error prevention measures for the connector, other measures can also be taken. For example, when using identification for error prevention, the branches of the connector can be error-proofed during the design of the wiring harness, or the connectors can be labeled to distinguish errors in this way; error prevention can be carried out by wrapping. This error prevention method mainly adopts different packaging and protection methods for different connectors and connecting parts when designing the wiring harness; error prevention can also be carried out through the layout direction of the wires and the surrounding environment. When designing the wiring harness, specific analysis should be conducted on different situations, and the ultimate goal of error prevention can be achieved by analyzing the different outlet directions designed for the same connector; finally, error prevention can also be carried out through fixed types. Different fixed methods should be adopted for different branches to implement the error prevention plan.

Conclusion

To sum up, in the design process of new energy vehicles, we must pay attention to its scientificity and rationality, pay attention to the error-proofing methods in the wiring harness design and connection, conduct specific analysis and application of various error-proofing methods, and reasonably solve the problems existing in the wiring harness design and connection of new energy vehicles, so as to better realize the improvement of the wiring harness level of new energy vehicles, realize the scientificity of automobile design and production to a greater extent, and improve the quality and efficiency of products.