071012_线束设计培训(共61张).pptx

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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 HuaWhat 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: No error无错误. No differen

2、t 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.Overview 1.System Planview系统拓普图2.Standard Circuit Introduction标准电路3.Schematics Reading and Comprehension电路图识读4.Layout design线束布局5.Cable

3、 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 chart材料明细BATTENGINELampLa

4、mpLic Lp1.Typical Electrical System PlanviewDR CO-DVRDOOR REARBODY REARFuel TankENGINEBATTERYINJECTIONTRANSMISSIONINSTRUMENTALFORWARD LAMPBODY MAINDOOR DRIVERdomeGENSTRBECBECBCMABSTCMECM EngineFuelTankLp SMLp SMECMSTARTERGeneratorBATTABS CEIMMOFBGND1GND1GND2GND22.5/2.56.0GND3GND3GND1:ABS CONTR.UNITG

5、ND1: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-1.0 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 CEN

6、TR-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:NUMBER 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

7、.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 CONTROL-2.5/2.5GND7:ECM CONTROL-2.5/2.5 GND7GND7GENERATOR W/HGND8GND8GND8:MAGNET COUPLE-0.5(PRE-ENG.)GND8:MAGNET COUPLE-0

8、.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-4.0 IMBO CONTR.UNIT-1.0 x2 IMBO CONTR.UNIT-1.0 x2 IP W/HSTEERING W/HA/C CONTROL BOXWIPER MOTORCENTRAL LOCK EC

9、U6.01.5GND9GND90.5GND9:ECM-0.5GND9:ECM-0.51.Typical Electrical System PlanviewLampLamp1.Typical Electrical System Planview (Contd)Region I: - Hot- WetRegion II: - Cool- DryRegion III: - Cool- WetUsage Environment1.Typical Electrical System Planview (Contd)Design is based on Usage Environment: uHot A

10、rea高温区域 High Temperature cable, like TXL, AVSX High Temperature Conduit,like PP, PA,EPTuCool Area低温区域 Low Temperature cable, like TWP, AVSS Low Temperature Conduit,like PE.uWet Area湿区 Sealed connector Sealed spliceuDry Area干区 Unsealed connector Unsealed splice1.Typical Electrical System Planview (Co

11、ntd)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: 干区域干区域Circuit StandardizationuWhe you see CKT# 140,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

12、orange. uCircuit standardization provides a common engineering language btw Packard and customeruDifferent customers have different method to standardize their CKTs.uESA-610 provides also standard Device 2. Standard Circuit Introduction2. Standard Circuit Introduction(Contd)3.Schematics Reading and

13、ComprehensionuBe Sure to Get Latest Schematics From Customer Before Harness Design!4.Layout design(Contd)u1. 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.u2. Provide proper branc

14、h 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 / tape 200 mm

15、, board congestion. Staggered lengths enable easy holder placement, less congestion, and easier build. 分支长度分支长度 前置式前置式 铰链式铰链式 后置式后置式6. 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u Too many “traps” exist in product handbook6. Connector ,Terminal , Seal and Plug

16、Selection(Contd)Things In HandbookReinforcement In Harness Drawing !u In-line Connector6. Connector ,Terminal , Seal and Plug Selection(Contd)+Question Every In-line Connectors that has no mounting clip!uTerminal selection is based on the circuit type, the crimp application, stock material, plating,

17、 stock thickness, current requirement, sealing 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 min

18、imize the number of terminals available, plated terminals 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

19、 and jeopardize the mechanical,electrical, and/or environmental 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 , Se

20、al and Plug Selection(Contd)uQuestion 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

21、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两者的端子最好使用相同镀层。相同镀层。uSeal 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

22、 WET area) that do not have a wire in each cavityuPrefered Loose Piece SealMP150:15324974,15324976,15324973MP280:15324983,5324984, 15324980, 15324981MP480: 15324987 ,15324988, 15324989,15324990, 15324991MP630: 15324993, 15324994, 15324995, 15324996, 15324997GT150:15366021,15366060GT280:15366065, 153

23、66066,153660676. Connector ,Terminal , Seal and Plug Selection(Contd)uPlugAvoid 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

24、 cavities will eliminate seals !没有空孔就不用密封！没有空孔就不用密封！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.Test points 1 2 3ElectrodeTest sample100 10Dimensions in millimetresAUWater Tightness

25、TestLeakage 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 i

26、n).Typical Immersion Test (SAE / ISO / USCAR)6. Connector ,Terminal , Seal and Plug Selection(Contd)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 th

27、e 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 resul

28、ting 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)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 nor

29、malize at 14.7psiFluid Dynamics(Scenario 5) 14.7 14.7 10.6 10.6- = - = -1051050 0 C C 0 00 0 C C(378 K) (273 K) Upon cooling, 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 6”depth can add 0.2psi

30、 of external pressure resulting in a -4.3 psi10.6 psi 00C14.7 psi 00CWhile hot, somehow the cable seals itself.6. Connector ,Terminal , Seal and Plug Selection(Contd)uExerciseConnector PN: 12052644Cable: M3101201(0.8 SQ)Terminal PN: ?Seal PN: ?6. Connector ,Terminal , Seal and Plug Selection(Contd)u

31、CadarUse Cadar to verify your selectionuComputer Aided Design Analysis Report uAlso called “Harness Analysis Report”uA group of 26 modules that automatically check for errors in harness wire & items chartsuApplication Engineer is the person to sign off CADAR reportuOnly after CADAR report is signed

32、off can the harness be released!6. Connector ,Terminal , Seal and Plug Selection(Contd)6. Connector ,Terminal , Seal and Plug Selection(Contd)uA quick view on “CADAR SUMMARY” reportuESA-605 SEARCH on the Engineering Page - To determine if an application for a terminal P/N and cable code(s) is alread

33、y validatedEnter Terminal P/NEnter a specific cable code(s) and/or size(s).OR Leave blank to view ALL cables validated for the selected terminal.Click on “Select All”6. Connector ,Terminal , Seal and Plug Selection(Contd)7.Tolerance and dimensionuEvery dimension on a W/A drawing has a specific toler

34、ance associated with 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.u5.2 Fixed points are datums, clips, clamps, and grommets (except taped-on

35、grommets). u150.0 +/- 15.0 mm, 150.0 MAX.150.0 MIN, or 150.0 REF.150.0+/-15150.0MAX150.0MIN150.0REF7.Tolerance and dimension(Contd)uTrends of Tolerance Chart This tolerance chart only for Old or Carry Over Designs !7.Tolerance and dimension(Contd)uTrends of Tolerance Chart. This tolerance chart are

36、recommended in ESA-740 for new GM new programs7.Tolerance and dimension(Contd)uTrends of Tolerance Chart. Some New Programs in GM are using the tolerance Charts above7.Tolerance and dimension(cont)uExercise: improve the dimensioning method for the following drawing7.Tolerance and dimension(cont)uExe

37、rcise: improve the dimensioning method for the following drawing8. Harness Covering Selection(contd)Taping Method Preferred Tape M2147021: 19mmM2147021: 19mmM2147001: 32mmGeneric PVC TapeOperating Temperature Maximum Temperature Preferred Conduit 8593M1883125155M1888120180M1889120-160180-200M4640 Ge

38、neric Conduit8. Harness Covering Selection(contd)For More Harness covering information, visithttp:/ Harness Covering Selection(contd)9.Splice Designu1. Minimize wires shorter than 150 mm.Short wires create quality problems due to handling difficulty. Potential safety hazard to operator hands due to

39、close proximity to splice press tooling.u2. Minimize the number of unbalanced sealed splices that differ by more than one lead (e.g. 3 X 1, 4 X 2)Processing problems are incurred while trying to seal an unbalanced splice causing quality problems.u3. Avoid the use of dissimilar wire lengths for seale

40、d splicesProcessing problems are incurred while trying to seal a splice with unequal mass on both sides of the splices. This also causes wire handling difficulties.u4. Question large splices (8 or more leads)High scrap rate (wrong leads often used). Difficult handling on splice press. Press mayrequi

41、re fixtures to keep leads separate. Long leads need modified splice buggies. Unbalanced splice with mixed gauges is worst case.Splice Design Generic Guideline9.Splice Design (contd)u5. Optimize splice locationsMinimize cable, optimize cutting, and standardize splice locations to provide for best lea

42、d prep and final assembly build processes. Consider wire lengths and cross sectional area.Minimum distance splice to splice or splice to outlet is 50 mm.u6. Minimize splices on small branchesSimplifies board tooling and harness assembly.Splice Design Generic Guideline(contd)注意！注意！除上述内容外，焊点排布还应注意下述几点

43、：除上述内容外，焊点排布还应注意下述几点：1）避免放在小分支内。）避免放在小分支内。2）避免放在有运动的分支处。）避免放在有运动的分支处。3）避免放在导线裸露处。）避免放在导线裸露处。4）避免）避免放在放在打弯、曲折处。打弯、曲折处。9.Splice Design (contd)Splicing method and Covering methodVs Quality,Cost PerformanceNote : For Reference Only9.Splice Design (contd)For more details, read10.Mounting Device Selection

44、uWiring must be retained to prevent pinching,entrapment or misroutinguWiring Must be retained at intervals less than 250mm, point to pointuUse thread-type fastneruUse clip tie to replace tape-on clips121863531542283111.Section View, Tape Back ,Hank and NotesSection ViewTo provide critical info on 2-

45、D drawingTape backTo hold optional content or facilitate VAP installation11.Section View, Tape Back ,Hank and Notes(contd)NotesTo provide critical info which can not be reflected on graphics12.Item and Circuit chartThe Endhttp:/ Page TrainingInfo/Training_Documentaion.htmOr S:EJV EngineeringtraininguVisit the following website to get more training materials演讲完毕，谢谢观看！