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Design and Selection of Automobile Wiring Harness

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As the neural network of the car, the car wiring harness plays the role of power distribution and signal transmission, which is very important for the safe driving of the car. Wire harness siphon water is a failure mode that is not easy to detect in automobile wiring harness. Therefore, it is particularly important to deal with the details that are prone to siphon in the wiring harness design process to improve the waterproof performance of the plug-in and the sealing performance of the wire.

After dissecting the connector of the main line and chassis harness, it is found that the wires of the harness are dry and clean, and there is no trace of water ingress. Continue to strip the wire behind the connector, and find that the copper wire is black and there are signs of water ingress. After dissecting all the wires of the chassis harness and tracing along the blackened path of the copper wire of the wire, it is found that not all the wires in the connector have traces of water ingress, but only some of the wires have water ingress and the copper wire is blackened. These wires correspond to the steering, braking and position signal wires of the left and right combination lamps outside the cabin. Therefore, it is suspected that water enters the waterproof connector of left and right rear combination lamp due to unqualified sealing. The water penetrates into the inside of the wire through the gap between the multi-strand cores of the wire and the differential pressure (mechanism of siphon phenomenon) caused by the height difference between the left and right rear combination lamp and the waterproof connector and the temperature change caused by the heating and cooling of the contacts in the waterproof connector in the cabin (mechanism of siphoning phenomenon), and then penetrates into the connector at the connector at the main wire, as shown in Fig. 3.