线束设计培训

1、Basic Harness DesignBasic Harness Design线束设计根底Delphi Packard Electric System EJV PEAugust,2003Presenter: Chen Shui HuaDelphi Confidential.What makes a good design? A good harness design shall be一个好的线束设计应包含如下: Reflect customers requirements exactly and completely充分准确的反映客户的要求.Quality质量要求: No error无错误.

2、No different meaning&Ambiguity 无歧义.Reliable: 10 Year or 170,000KM 可靠性为10年或17万公里.Low cost低本钱Attain Cost Goal 思索本钱要求.VAVE 价值工程分析EC4 本钱节余Buildability:可操作性Easy to build便于制造.Delphi Confidential.Overview 1.System Planview系统拓普图2.Standard Circuit Introduction规范电路3.Schematics Reading and Comprehension电路图识读4.

3、Layout design线束规划5.Cable Selection And circuit profection导线选择6. Connector,Terminal ,Seal and Plug selection 插接器,端子,密封,盲栓选取7.Tolerance and dimension尺寸公差8.Harness Covering Selection覆盖物选取9.Splice Design焊接设计10.Mounting Device Selection固定件选取11.Section View, Tape Back ,Hank and Notes,零件图12.Item and wire c

4、hart资料明细Delphi Confidential.BATTENGINELampLampLic Lp1.Typical Electrical System PlanviewDR CO-DVRDOOR REARBODY REARFuel TankENGINEBATTERYINJECTIONTRANSMISSIONINSTRUMENTALFORWARD LAMPBODY MAINDOOR DRIVERdomeGENSTRBECBECBCMABSTCMECMDelphi Confidential. EngineFuelTankMDL LampMDL LampLp SMLp SMECMSTARTE

5、RGeneratorBATTABS CEIMMOFBGND1GND22.5/2.56.0GND3GND1:ABS CONTR.UNITGND2:SIDE BLINKER-1.0 x2 KP A/C-2.5 CE-6.0 HEAD LP-1.5 FOG LP-1.0 TURN SIGNAL-1.0 x2 GND3:ROOM LGT-0.5 GEAR RANKING INDICATOR-0.5 CENTR-LOCK LEFT-1.0 POWER WINDOW-0.35x4 CENTR-LOCK ECU-2.5 ELE-MIRROR-0.35 6.00.5GND4:OIL TANK SNSR-0.5

6、GND5:NUMBER PLATE LGT-1.0 x2 BOOT LGT-0.5 READING LGT-0.5x2(OPTION) 2.5GND4GND5GND6GND6:3rd BRAKE LGT-1.0 TAIL LGT-1.0 x2 ENGINE W/HBODY W/HPRE-ENGINE W/HHEAD LIGHT W/H2.5/2.5GND7:ECM CONTROL-2.5/2.5 GND7GENERATOR W/HGND8GND8:MAGNET COUPLE-0.5(PRE-ENG.) MOTOR CONTROL-1.0(PRE-ENG.) RUV4-1.5(PRE-ENG.)

7、 HT-RESISTANCE-0.5(PRE-ENG.) COOLING FAN-4.0 IMBO CONTR.UNIT-1.0 x2 IP W/HSTEERING W/HA/C CONTROL BOXWIPER MOTORCENTRAL LOCK ECU6.01.5GND90.5GND9:ECM-0.51.Typical Electrical System Planview.LampLamp1.Typical Electrical System Planview (Contd)Region I: - Hot- WetRegion II: - Cool- DryRegion III: - Co

8、ol- WetUsage EnvironmentDelphi Confidential.1.Typical Electrical System Planview (Contd)Design is based on Usage Environment: Hot Area高温区域High Temperature cable, like TXL, AVSXHigh Temperature Conduit,like PP, PA,EPTCool Area低温区域Low Temperature cable, like TWP, AVSSLow Temperature Conduit,like PE.We

9、t Area湿区Sealed connectorSealed spliceDry Area干区Unsealed connectorUnsealed spliceDelphi Confidential.1.Typical Electrical System Planview (Contd)门线束的特别之处: 门钢板线束部分: 湿区域门钢板内饰线束部分: 干区域Delphi Confidential.Circuit StandardizationWhe you see CKT# 140,you can get following information from ESA-610:The Descr

10、iption of this ckt is: FUSE OUTPUT-BATTERY-TYPE III FUSE This is a “ Hot on all time circuit.It is the output of a minifuse.Color is orange. Circuit standardization provides a common engineering language btw Packard and customerDifferent customers have different method to standardize their CKTs.ESA-

11、610 provides also standard Device 2. Standard Circuit IntroductionRef to ESA-610Delphi Confidential.2. Standard Circuit Introduction(Contd)Ref to ESA-610Delphi Confidential.3.Schematics Reading and ComprehensionBe Sure to Get Latest Schematics From Customer Before Harness Design!Delphi Confidential.

12、4.Layout design(Contd)Delphi Confidential.1. Question outlets with 4 or more branches公共节点分支不能超越4个.Complicated board design, congested board, difficult to tape, and difficult to build复杂的案板设计,缠绕困难, 操作困难.2. Provide proper branch length from outlet to back of connector从节点到插接器末端的分支长度:outlet / outlet:A. 1

13、st connector / outlet: length 200 mm.第一个分支长度200mm.B. 2nd connector/ outlet: length 250 mm.第一个分支长度200mm.C. 3rd connector / outlet: length 300 mm.第一个分支长度200mm.Difficult to build / tape 200 mm, board congestion. Staggered lengths enable easy holder placement, less congestion, and easier build. 分支长度 前置式

14、 铰链式 后置式Delphi Confidential.6. Connector ,Terminal , Seal and Plug Selection(Contd)横插式锁紧后置式锁紧铰链式锁紧Delphi Confidential. Too many “traps exist in product handbook6. Connector ,Terminal , Seal and Plug Selection(Contd)Things In HandbookReinforcement In Harness Drawing !Delphi Confidential. In-line Conn

15、ector6. Connector ,Terminal , Seal and Plug Selection(Contd)+Question Every In-line Connectors that has no mounting clip!Delphi Confidential.Terminal selection is based on the circuit type, the crimp application, stock material, plating, stock thickness, current requirement, sealing requirements, bl

16、ade width, etc. Plated terminals shall be used in harsh environments. A variety of plating materials is available if necessary to meet performance criteria. Caution:dissimilar materials can have unwanted chemical reactionsIn order to minimize the number of terminals available, plated terminals are r

17、ecommended for all applications.During terminal selection, the engineer should review the terminal at the opposite end of the wire, taking into consideration that manufacturing could possibly plug the opposite terminal into the connector and jeopardize the mechanical,electrical, and/or environmental

18、 performance. (Example: thin vs. regular stock plated vs. selective plating) Terminal Stabilizer: Mylar this component is used in large connectors with male blades to position terminals and reduce bent blades. 6. Connector ,Terminal , Seal and Plug Selection(Contd)Delphi Confidential.Question the ne

19、cessity of Gold/Silver plated terminal6. Connector ,Terminal , Seal and Plug Selection(Contd)It would be better they have same plating in both connector terminal and Device pins!Contact of different plating may cause chemical reaction !不同镀层的端子能够会产生不良的化学反响插接器与用电器两者的端子最好运用一样镀层。Delphi Confidential.Seal

20、 Selection is based on wire OD, connector cavity size, and terminal type.Cost saving: Use loose Piece seal rather that mylar seal6. Connector ,Terminal , Seal and Plug Selection(Contd)A cavity plug is required in sealed connectors (in WET area) that do not have a wire in each cavityDelphi Confidenti

21、al.Prefered Loose Piece SealMP150:15324974,15324976,15324973MP280:15324983,5324984, 15324980, 15324981MP480: 15324987 ,15324988, 15324989,15324990, 15324991MP630: 15324993, 15324994, 15324995, 15324996, 15324997GT150:15366021,15366060GT280:15366065, 15366066,153660676. Connector ,Terminal , Seal and

22、 Plug Selection(Contd)Delphi Confidential.PlugAvoid using plug in connectorMaximum allowable plugs in one connector is 2 pcsIf plug is unavoidablechange the connector“Flash over the unused Cavities6. Connector ,Terminal , Seal and Plug Selection(Contd)“Flash-Over unused cavities will eliminate seals

23、 !没有空孔就不用密封！: Flash-Over LegendDelphi Confidential.Sealed connectors IPX7The leakage current shall not exceed 50 A at 48 V applied voltage. Sealed connectors tested shall also fulfill the High Pressure Spray test.Water Tightness TestLeakage current is measure between adjacent contactsThis typical im

24、mersion test setup is used to detect if water gets into the connector by checking resistance between contacts. (Remember that we arent concerned with air getting out of a connector e.g. a pressure test but rather water getting in).Typical Immersion Test (SAE / ISO / USCAR)6. Connector ,Terminal , Se

25、al and Plug Selection(Contd)Delphi Confidential.Fluid Dynamics(Scenario 4)14.7 psi 1050C18.8 psi 1050C Heated to 1050C, and assuming no air can escape, the pressure inside raises to 18.8 psi and outside of course is still atmospheric pressure so the result is a 4.1 psi internal pressure. 14.7 18.8 =

26、 230 C 1050 C (296 K) (378 K) Cooling to 0 C the pressure reduces to 13.6 psi resulting in a -1.1 psi.* If the cooling is performed by immersion into 6 of water, the 6depth can add 0.2 psi of external pressure resulting in a -1.3 psi.13.6 psi 00 C14.7 psi 00 C 18 .8 13.6 = 1050 C 00 C(378 K) (273 K)

27、 6. Connector ,Terminal , Seal and Plug Selection(Contd)Delphi Confidential.14.7 psi 1050C14.7 psi 1050C Heated to 1050C, and assuming air can escape down the core of the wire, the pressure inside will normalize at 14.7psiFluid Dynamics(Scenario 5) 14.7 10.6 = 1050 C 00 C(378 K) (273 K) Upon cooling

28、, air cannot return and so the pressure decreases to 10.6 psi which results in a -4.1psi.* If the cooling is performed by immersion into 6 of water, the 6depth can add 0.2psi of external pressure resulting in a -4.3 psi10.6 psi 00C14.7 psi 00CWhile hot, somehow the cable seals itself.6. Connector ,T

29、erminal , Seal and Plug Selection(Contd)Delphi Confidential.ExerciseConnector PN: 12052644Cable: M3101201(0.8 SQ)Terminal PN: ?Seal PN: ?6. Connector ,Terminal , Seal and Plug Selection(Contd)Delphi Confidential.CadarUse Cadar to verify your selectionComputer Aided Design Analysis Report Also called

30、 “Harness Analysis ReportA group of 26 modules that automatically check for errors in harness wire & items chartsApplication Engineer is the person to sign off CADAR reportOnly after CADAR report is signed off can the harness be released!6. Connector ,Terminal , Seal and Plug Selection(Contd)Delphi

31、Confidential.6. Connector ,Terminal , Seal and Plug Selection(Contd)A quick view on “CADAR SUMMARY reportDelphi Confidential.ESA-605 SEARCH on the Engineering To determine if an application for a terminal P/N and cable code(s) is already validatedEnter Terminal P/NEnter a specific cable code(s) and/

32、or size(s).Then SUBMIT your request.OR Leave blank to view ALL cables validated for the selected terminal.Click on “Select All6. Connector ,Terminal , Seal and Plug Selection(Contd)Delphi Confidential.7.Tolerance and dimensionEvery dimension on a W/A drawing has a specific tolerance associated with

33、it. The tolerance can be specified with the dimension. Example: 150.0 +/- 15.0 mm, 150.0 MAX.150.0 MIN, or 150.0 REF. When the tolerance is not specified on the drawing, use the tolerance chart specified.5.2 Fixed points are datums, clips, clamps, and grommets (except taped-on grommets). 150.0 +/- 1

34、5.0 mm, 150.0 MAX.150.0 MIN, or 150.0 REF.150.0+/-15150.0MAX150.0MIN150.0REFDelphi Confidential.7.Tolerance and dimension(Contd)Trends of Tolerance Chart This tolerance chart only for Old or Carry Over Designs !Delphi Confidential.7.Tolerance and dimension(Contd)Trends of Tolerance Chart. This toler

35、ance chart are recommended in ESA-740 for new GM new programsDelphi Confidential.7.Tolerance and dimension(Contd)Trends of Tolerance Chart. Some New Programs in GM are using the tolerance Charts aboveDelphi Confidential.7.Tolerance and dimension(cont)Exercise: improve the dimensioning method for the

36、 following drawingDelphi Confidential.7.Tolerance and dimension(cont)Exercise: improve the dimensioning method for the following drawingDelphi Confidential.8. Harness Covering Selection(contd)Taping Method Preferred Tape M2147021: 19mmM2147021: 19mmM2147001: 32mmGeneric PVC TapeDelphi Confidential.O

37、perating Temperature Maximum Temperature Preferred Conduit 8593M1883125155M1888120180M1889120-160180-200M4640 Generic Conduit8. Harness Covering Selection(contd)Delphi Confidential.For More Harness covering information, visitdelphip.ped.gmeds/ac2_pasd_hcs/Index.htm8. Harness Covering Selection(contd

38、)Delphi Confidential.9.Splice Design1. Minimize wires shorter than 150 mm.Short wires create quality problems due to handling difficulty. Potential safety hazard to operator hands due to close proximity to splice press tooling.2. Minimize the number of unbalanced sealed splices that differ by more t

39、han one lead (e.g. 3 X 1, 4 X 2)Processing problems are incurred while trying to seal an unbalanced splice causing quality problems.3. Avoid the use of dissimilar wire lengths for sealed splicesProcessing problems are incurred while trying to seal a splice with unequal mass on both sides of the spli

40、ces. This also causes wire handling difficulties.4. Question large splices (8 or more leads)High scrap rate (wrong leads often used). Difficult handling on splice press. Press mayrequire fixtures to keep leads separate. Long leads need modified splice buggies. Unbalanced splice with mixed gauges is worst case.Splice Design Generic GuidelineDelphi Confidential.9.Splice Design (contd)5. Optimize splice locationsMinimize cable, optimize cutting, and standardize splice locations to provide for best lead prep and final assem