Calculation 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.

automobile wiring harness
Konnra wiring harness engineers provide you with a theoretical calculation method (wire harness standard algorithm) for estimating the outer diameter of automotive wiring harnesses.
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 wire harness segment, and Si represents the cross-sectional area of the i-th wire)
We default the cross section of the harness segment to a circle, then:
(In the formula, D is the diameter of the wire harness section, 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 electrical components in the whole vehicle, the German standard wire is used more and more. Here we also select examples of German marking lines for related explanations.
German standard wire
It is worth mentioning that the 0.5 wire usually 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 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=5.6 found by formula 2
1) If this section of line is defined to be wrapped with tape, and the tape thickness is 0.14, the diameter of the wire harness end is D=5.6+0.14x2=5.88, taking the integer 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 the line defines the 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. The outer diameter of the bellows is 10mm, then the outer diameter of the wire harness section is considered to be 10mm.

The wire harness data designer can suggest relevant Excel tables with calculation formulas, or based on actual work experience or measurement, to establish a statistical table of the cross-sectional outer diameter of each branch of the relevant wire harness of a typical model, so that it can be quickly and conveniently carried out. Path estimation.




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