With the improvement of vehicle intelligence and electrification, the number of electronic devices in the car is increasing, and the vehicle wiring harness manufacturing process is becoming more and more important. A vehicle harness is a set of cables and connectors that connect the various electrical components of a vehicle. The manufacturing process of wire harness is directly related to the connection quality and safety of vehicle electrical components. This paper will discuss the importance of vehicle wire harness manufacturing process from the perspective of safety.

First, the wiring harness manufacturing process has a decisive impact on the connection quality of vehicle electrical components

In the manufacturing process of vehicle wire harnesses, cables, connectors, insulation sleeves and other components need to be selected and processed. Only the selection of appropriate cables and different specifications, different types of connectors, and the correct processing, welding, crimping, in order to ensure the quality of the connection. Wiring harness manufacturing is not standardized, the cable is prone to kneading or wear, the live part is easy to short circuit or discharge, resulting in a variety of problems, serious more likely to cause fire, explosion and other safety accidents.

2. Safety accident cases

Wiring harness manufacturing non-standard has caused a number of vehicle safety accidents:

1. In 2009, Gree air conditioning had a problem with the welding of the wiring harness joint, resulting in a fire accident during startup;

2. In 2015, due to wiring harness quality problems, Subaru's vehicle air conditioning module short-circuiting led to vehicle fire;

3. In August 2018, U.S. Volkswagen Group recalled about 8,700 vehicles due to a wiring harness problem with loose wiring harness joint nuts, resulting in the failure of air bags, pretensioners or seat belts, which can lead to death or injury.

The above vehicle safety accidents are caused by the wiring harness manufacturing process is not standardized, resulting in electrical component connection problems, highlighting the wiring harness manufacturing process is crucial to vehicle safety.

Third, the impact of wire harness manufacturing process on vehicle safety

1. Ensure the normal operation of the vehicle electrical system. The wiring harness manufacturing process specification is directly related to the connection quality and safety of vehicle electrical components. Once the connection is not strong, it is easy to lead to abnormal current, affecting the normal operation of the vehicle electrical system, and then affecting the safe driving of the vehicle.

2. Prevent wire harness aging hazards. The service life of the wire harness is also limited, with the passage of time, the insulation layer in the wire harness will age, deteriorate, embrittlement, such as the wire harness manufacturing is not standardized, inferior materials, do not meet the requirements of processing and other factors, will greatly aggravate the aging speed of the wire harness.

3. Prevent dangerous events such as fire and explosion. Vehicle wiring harness manufacturing is not standardized, the cable is easy to knead or wear, easy to short circuit or spark, and more likely to cause fire, explosion and other safety accidents in serious cases.

Fourth, harness manufacturing technology innovation

In modern vehicles, with the increase of the number of vehicle electrical components, the amount of wiring harness becomes larger and larger, and the wiring harness manufacturing process becomes more important. In recent years, the wiring harness manufacturing process at home and abroad is also constantly undergoing technological innovation to improve the safety, reliability and quality level of wiring harness manufacturing, such as:

1. Automatic manufacturing technology: The use of wire harness automatic loom and automatic wire stripping and shearing machine for processing, greatly improve the production efficiency and quality of wire harness;

2. Precision machining technology: Using computer numerical control technology to accurately control the processing size and precision of the wire harness;

3. Automatic detection technology: The use of automatic video detector to detect the surface of the wire harness to achieve a comprehensive detection of the quality of the wire harness.

Improving the manufacturing process level of wire harnesses can not only improve the safety of vehicles, but also continuously improve the performance and service life of vehicles.

In short, the wiring harness manufacturing process is one of the most important links in modern vehicles, for the vehicle electrical component connection quality, vehicle safety has a decisive impact, we must pay attention to the wiring harness manufacturing process standardization, standardization, combined with automatic manufacturing, precision processing and automatic testing and other technological innovation, improve the precision and reliability of wiring harness manufacturing technology. At the same time, strengthen the quality supervision and management of the wiring harness manufacturing process, ensure the safety of the vehicle wiring harness, and truly protect the life safety of vehicles and personnel.