071012_线束设计培训.ppt

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1、Basic Harness DesignBasic Harness Design线束设计基础线束设计基础Delphi Packard Electric System EJV PEAugust,2003Presenter:Chen Shui Hua2021/9/26Delphi Confidential1What makes a good design?A good harness design shall be一个好的线束设计应包含如下:uReflect customers requirements exactly and completely充分准确的反映客户的要求.uQuality质量要求

2、:No error无错误.No different meaning&Ambiguity 无歧义.Reliable:10 Year or 170,000KM 可靠性为10年或17万公里.uLow cost低成本Attain Cost Goal 考虑成本要求.VAVE 价值工程分析EC4 成本节余uBuildability:可操作性Easy to build便于制造.2021/9/26Delphi Confidential2Overview 1.System Planview系统拓普图2.Standard Circuit Introduction标准电路3.Schematics Reading a

3、nd Comprehension电路图识读4.Layout design线束布局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

4、图12.Item and wire chart材料明细2021/9/26Delphi Confidential3BATTENGINELampLampLic Lp1.Typical Electrical System PlanviewDR CO-DVRDOOR REARBODY REARFuel TankENGINEBATTERYINJECTIONTRANSMISSIONINSTRUMENTALFORWARD LAMPBODY MAINDOOR DRIVERdomeGENSTRBECBECBCMABSTCMECM2021/9/26Delphi Confidential4 EngineFuelTa

5、nkMDL LampMDL LampLp SMLp SMECMSTARTERGeneratorBATTABS CEIMMOFBGND1GND1GND2GND22.5/2.56.0GND3GND3GND1:ABS CONTR.UNITGND1:ABS CONTR.UNITGND2:SIDE BLINKER-1.0 x2 GND2:SIDE BLINKER-1.0 x2 KP A/C-2.5 KP A/C-2.5 CE-6.0 CE-6.0 HEAD LP-1.5 HEAD LP-1.5 FOG LP-1.0 FOG LP-1.0 TURN SIGNAL-1.0 x2 TURN SIGNAL-1.

6、0 x2 GND3:ROOM LGT-0.5GND3:ROOM LGT-0.5 GEAR RANKING INDICATOR-0.5 GEAR RANKING INDICATOR-0.5 CENTR-LOCK LEFT-1.0 CENTR-LOCK LEFT-1.0 POWER WINDOW-0.35x4 POWER WINDOW-0.35x4 CENTR-LOCK ECU-2.5 CENTR-LOCK ECU-2.5 ELE-MIRROR-0.35 ELE-MIRROR-0.35 6.00.5GND4:OIL TANK SNSR-0.5GND4:OIL TANK SNSR-0.5GND5:N

7、UMBER PLATE LGT-1.0 x2 GND5:NUMBER PLATE LGT-1.0 x2 BOOT LGT-0.5 BOOT LGT-0.5 READING LGT-0.5x2(OPTION)READING LGT-0.5x2(OPTION)2.5GND4GND4GND5GND5GND6GND6GND6:3rd BRAKE LGT-1.0GND6:3rd BRAKE LGT-1.0 TAIL LGT-1.0 x2 TAIL LGT-1.0 x2 ENGINE W/HBODY W/HPRE-ENGINE W/HHEAD LIGHT W/H2.5/2.5GND7:ECM CONTRO

8、L-2.5/2.5GND7:ECM CONTROL-2.5/2.5 GND7GND7GENERATOR W/HGND8GND8GND8:MAGNET COUPLE-0.5(PRE-ENG.)GND8:MAGNET COUPLE-0.5(PRE-ENG.)MOTOR CONTROL-1.0(PRE-ENG.)MOTOR CONTROL-1.0(PRE-ENG.)RUV4-1.5(PRE-ENG.)RUV4-1.5(PRE-ENG.)HT-RESISTANCE-0.5(PRE-ENG.)HT-RESISTANCE-0.5(PRE-ENG.)COOLING FAN-4.0 COOLING FAN-4

9、.0 IMBO CONTR.UNIT-1.0 x2 IMBO CONTR.UNIT-1.0 x2 IP W/HSTEERING W/HA/C CONTROL BOXWIPER MOTORCENTRAL LOCK ECU6.01.5GND9GND90.5GND9:ECM-0.5GND9:ECM-0.51.Typical Electrical System Planview2021/9/26Delphi ConfidentialLampLamp1.Typical Electrical System Planview(Contd)Region I:-Hot-WetRegion II:-Cool-Dr

10、yRegion III:-Cool-WetUsage Environment2021/9/26Delphi Confidential61.Typical Electrical System Planview(Contd)Design is based on Usage Environment:uHot Area高温区域High Temperature cable,like TXL,AVSXHigh Temperature Conduit,like PP,PA,EPTuCool Area低温区域Low Temperature cable,like TWP,AVSSLow Temperature

11、Conduit,like PE.uWet Area湿区Sealed connectorSealed spliceuDry Area干区Unsealed connectorUnsealed splice2021/9/26Delphi Confidential71.Typical Electrical System Planview(Contd)门线束的特别之处:门钢板线门钢板线束部分束部分:湿区域湿区域门钢板内门钢板内饰线束部饰线束部分分:干区干区域域2021/9/26Delphi Confidential8Circuit StandardizationuWhe you see CKT#140,

12、you can get following information from ESA-610:The Description 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.uCircuit standardization provides a common engineering language btw Packard and customeruDifferent customer

13、s have different method to standardize their CKTs.uESA-610 provides also standard Device 2.Standard Circuit IntroductionRef to ESA-6102021/9/26Delphi Confidential92.Standard Circuit Introduction(Contd)Ref to ESA-6102021/9/26Delphi Confidential103.Schematics Reading and ComprehensionuBe Sure to Get L

14、atest Schematics From Customer Before Harness Design!2021/9/26Delphi Confidential114.Layout design(Contd)2021/9/26Delphi Confidential12u1.Question outlets with 4 or more branches公共节点分支不能超过公共节点分支不能超过4个个.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

15、.u2.Provide proper branch length from outlet to back of connector从节点到插接器末端的分从节点到插接器末端的分支长度支长度:outlet/outlet:A.1st connector/outlet:length 200 mm.第一个分支长度第一个分支长度200mm.B.2nd connector/outlet:length 250 mm.第一个分支长度第一个分支长度200mm.C.3rd connector/outlet:length 300 mm.第一个分支长度第一个分支长度200mm.Difficult to build/ta

16、pe 200 mm,board congestion.Staggered lengths enable easy holder placement,less congestion,and easier build.分支长度分支长度200mm制作困难制作困难,长度错开尽可能的达长度错开尽可能的达到到holder容易摆放容易摆放,低密度低密度,容易制作容易制作.u3.Communize side and direction of branch breakouts对于节点相同伸出方向不同的分支对于节点相同伸出方向不同的分支:Easier build:easier to tape,apply cond

17、uit,and better board layout.Consistent plugging direction.u4.Eliminate outlets less than 100 mm apart-evaluate combining outlets尽量减少分支节点尽量减少分支节点间尺寸低于间尺寸低于100mm的布置。的布置。Very difficult to build and tape.Creates congested board area,and may require special tooling and added build steps.4.Layout designRe

18、f to ESA-740 and/or DFM handbook2021/9/26Delphi Confidential13u5.Communize outlets and branch lengths between part numbers。u6.Avoid closed outlets尽量减少封闭式节点尽量减少封闭式节点Significant increased labor penalty if outlets are taped closed.Use closed outlets where containment,relative motion,vibration,abrasion,

19、appearance,or abrasive contaminants(grit)is an issue-primarily under hood and chassis.u7.Eliminate plastic tees and conduit ends 取消取消T型塑件和波纹管管夹型塑件和波纹管管夹.Taping is less expensiveu8.Consider elimination of dress covers to drive significant cost savings考虑减少表面覆盖物的使用数量考虑减少表面覆盖物的使用数量Contain wires with:vin

20、yl spot tape(s)first choicesplice tape(s)second choicewire tie(s)third choiceu9.Eliminate like color leads adjacent to each other in an in-line connector避免在同一个连接件内出现颜色相近的导线避免在同一个连接件内出现颜色相近的导线.Can cause mis-plugs,and crossed wires4.Layout design(Contd)2021/9/26Delphi Confidential14u10.Consider error

21、proofing like connectors adjacent to each other to assure they are not mis-plugged避免在相邻位置上使用类似的插接避免在相邻位置上使用类似的插接器器,以防止插接错误以防止插接错误Consider indexing connectors differently;dont rely only on different color connectorsu11.Minimize the number of connectors where possible尽可能减少尽可能减少插接器的零件种类插接器的零件种类.Conside

22、r combining two or more small connectors with one low engage connectoru12.Commonize wire gauges on leads out of splices if they have similar terminals and length避免相同端子、相同长度、不同线径的导线在同一避免相同端子、相同长度、不同线径的导线在同一焊点伸出焊点伸出.If smaller gauge lead is plugged into a cavity requiring large gauge lead then electri

23、cal problems may result.Mis-plugs cannot be detected by ring-out in this situation.Commonizing to largest gauge will prevent effects of mis-plugs.u13.Question the use of 4 or more wires in twisted cable 避免使用避免使用4根根(或以上或以上)绞合线绞合线.Very difficult build and added tooling expense to build4.Layout design(

24、Contd)2021/9/26Delphi Confidential15Redesign II Harness partitioning proposals(Layout)Jul.9.2002 Proposal1:combine 4 part numbers to 1:1.IP 1GD 971 315XX 2.Body harness 1GD 971 135XX 3.Lenkstock 1GD 971 063XX 4.Headlamp 1GD 971 071XX requirements:1.a hole with diameter of 58-60mm on front panel;2.De

25、velopment a new grommet to fit the hole.Proposal 2.Combine following 3 part numbers to 1:1.IP 1GD 971 315XX 2.Body harness 1GD 971 135XX 3.Lenkstock 1GD 971 063XX The others keep original part numbers 4.Layout design(Contd)2021/9/26Delphi ConfidentialRedesign II Harness partitioning decision(Layout)

26、Jul.11.2002 After discussion with FAW-VW PE-EE Mgr.Liu Yong,the decision was made as following:No possibility to change the body(like to get new holes)combine 3 part numbers to 1:1.IP 1GD 971 315XX 1.1GD 971 051XX 2.Body harness 1GD 971 135XX 3.Lenkstock 1GD 971 063XX 2.1GD 971 071XX 3.1GD 971 072/7

27、74XX 4.1GD 971 610XX 5.1GD 971 349A 6.1GD 971 225A 7.1GD 971 235 8.1GD 971 537 9.165 971 487 10.1GD 971 160B Only for no IFL 11.1GD 971 161 Items 1-3 will create new status For IFL:harnesses 1-8 are needed;for old IFL vehicles:1-11 are needed.Or separate 1GD 971 071XX into two functions,1 part(relat

28、ed to light)added to main harness,others related to ABS function keep the original status,re-create ABS harness 1GD 971 279.4.Layout design(Contd)2021/9/26Delphi Confidential5.Cable Selection导导 线线一组用于信号或动力传递，有绝缘层保护的金属导体。导导 线线 结结 构构绝缘层(PVC)导体(Copper,Cu 铜)2021/9/26Delphi Confidential185.Cable Selectio

29、n2021/9/26Delphi Confidential195.Cable SelectionCableSAEJISDINTWPTXLSGX:Battery:M1643STX:M3252Fusible Link:M3382R 5:M3267M3075M3099M3322M3089M3096GXL:M3101 FlexibleSTT:From Generator to Starter:M3391Drain Wire:M3098uCable Selection is based on the following consideration:原理图原理图环境温度环境温度顾客户要求顾客户要求标准标准

30、硬度硬度负荷负荷伸缩性伸缩性特殊要求特殊要求成本成本2021/9/26Delphi Confidential205.Cable Selection(contd)SAE cable General Guideline SAE导线标准TWPTXLM3096M30890.35 SQ0.8 SQ1.0 SQ0.5 SQ2.0 SQ3.0 SQ5.0 SQM3099M30750.35 SQ0.8 SQ1.0 SQ0.5 SQ2.0 SQ3.0 SQ5.0 SQuCost Saving成本节余成本节余7 strands replaced 19 strands7股替代股替代19股。股。uQuality Im

31、provement质量改进质量改进Annealed cable replaces Harddrawn退货导线替代冷抽导线。退货导线替代冷抽导线。2021/9/26Delphi Confidential215.Cable Selection(contd)2021/9/26Delphi Confidential22Rule of Thumb Fuse to Cable Size CABLE SIZE FUSE SIZESAEISOJIS AMPS .13.13 -5.22.22 -7.5.35.35,.50.30 10.50.75.50 15.801.0.85 201.01.51.25 252.0

32、2.52.0 303.04.03.0 405.04.05.0 505.06.05.0 605.Cable Selection(contd)2021/9/26Delphi Confidential235.Cable Selection(contd)要求更高的温度的导线怎么办?:M3235(260C)要求超级柔软导线怎么办?M3101要求自动变速箱里面的导线怎么办?M3267气囊线束的导线怎么办?:M3322 和M3393要求电池的导线怎么办?M1643,M3391和M3252可熔断导线怎么办？:M3382线太粗怎么办？:用Din Cable用光纤怎么办？:M3098用绞股线怎么办？:M48765

33、.0 SQ2021/9/26Delphi Confidential24 6.Connector,Terminal,Seal and Plug SelectionuConnector SelectionImportant features to be considered during connector selection are availability of terminal position assurance(TPA)or Positive Lock reinforcement(PLR),connector position assurance(CPA),engage force,po

34、sitive connector seal retention,and primary lock feature.Pull To Seat Connector System:It is recommended that this connection series not be used for new applications or proliferated.Ref to Circuit protection,ESA-740 and product handbook2021/9/26Delphi Confidential25 6.Connector,Terminal,Seal and Plu

35、g Selection(Contd)uGT replacement for PTS connectorsAll PTS connector has GT Replacement.Ref to Circuit protection,ESA-740 and product handbookOr2021/9/26Delphi Confidential26 uIt is NOT enough to make selection from HandbookuYou Must be an expert to know the insight of connectionMake sure that term

36、inal in connector are dual fail-safeQuestion connectors without TPA(or hinge)Remove any CPA if possible.Ref to Circuit protection,ESA-740 and product handbook6.Connector,Terminal,Seal and Plug Selection(Contd)+=-CPATPA后置式二次锁紧后置式二次锁紧关于二次锁紧形式的安全程度；关于二次锁紧形式的安全程度；横插式横插式 前置式前置式 铰链式铰链式 后置式后置式2021/9/26Delp

37、hi Confidential276.Connector,Terminal,Seal and Plug Selection(Contd)横插式锁紧横插式锁紧后置式锁紧后置式锁紧铰链式锁紧铰链式锁紧2021/9/26Delphi Confidential28u Too many“traps”exist in product handbook6.Connector,Terminal,Seal and Plug Selection(Contd)Things In HandbookReinforcement In Harness Drawing!2021/9/26Delphi Confidential

38、29u In-line Connector6.Connector,Terminal,Seal and Plug Selection(Contd)+Question Every In-line Connectors that has no mounting clip!2021/9/26Delphi Confidential30uTerminal selection is based on the circuit type,the crimp application,stock material,plating,stock thickness,current requirement,sealing

39、 requirements,blade 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 term

40、inals are recommended 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 envir

41、onmental 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)2021/9/26Delphi Confidential31uQuestio

42、n the necessity 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!不同镀层的端子不同镀层的端子可能会产生不良可能会产生不良的化学反应的化学反应插接器与用电器两者的端子最好使用插接器与用电器

43、两者的端子最好使用相同镀层。相同镀层。2021/9/26Delphi Confidential32uSeal 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)uA cavity plug is required in sealed connectors(in WET area)that do n

44、ot have a wire in each cavity2021/9/26Delphi Confidential33uPrefered Loose Piece SealMP150:15324974,15324976,15324973MP280:15324983,5324984,15324980,15324981MP480:15324987,15324988,15324989,15324990,15324991MP630:15324993,15324994,15324995,15324996,15324997GT150:15366021,15366060GT280:15366065,15366

45、066,153660676.Connector,Terminal,Seal and Plug Selection(Contd)2021/9/26Delphi Confidential34uPlugAvoid 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)

46、“Flash-Over”unused cavities will eliminate seals!没有空孔就不用密封！没有空孔就不用密封！:Flash-Over Legend2021/9/26Delphi Confidential35Sealed 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 TestLe

47、akage current is measure between adjacent contactsuThis typical immersion 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).Typic

48、al Immersion Test(SAE/ISO/USCAR)6.Connector,Terminal,Seal and Plug Selection(Contd)2021/9/26Delphi Confidential36Fluid 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 pre

49、ssure so the result is a 4.1 psi internal pressure.14.714.7 18.8 18.8-=-=-23 230 0 C 105C 1050 0 C 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 6”depth can add 0.2 psi of external pressure resultin

50、g in a-1.3 psi.13.6 psi 00 C14.7 psi 00 C 18.8 18.8 13.6 13.6-=-=-1051050 0 C C 0 00 0 C C(378 K)(273 K)6.Connector,Terminal,Seal and Plug Selection(Contd)2021/9/26Delphi Confidential3714.7 psi 1050C14.7 psi 1050C Heated to 1050C,and assuming air can escape down the core of the wire,the pressure ins