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What are the standards and requirements for selecting raw materials for automotive wiring harnesses (such as copper wire, insulation materials, etc.)? In the production of automotive electrical appliances, how to select and test various electrical components (such as relays, sensors, switches, etc.)?
In the field of automotive wiring harness and electrical appliance manufacturing, the selection of raw materials and the testing of electrical components are key links to ensure product quality and performance. Our company, with its deep industry accumulation and technological innovation, strictly follows a series of high-standard and strict processes, and is committed to providing customers with excellent automotive wiring harness and electrical solutions.
Selection standards and requirements for raw materials for automotive wiring harnesses
1. Selection of copper wire
Standards and requirements: The copper wire in the automotive wiring harness is the conductive core, and its quality is directly related to the efficiency and safety of current transmission. We strictly follow the International Electrotechnical Commission (IEC) and relevant standards of the automotive industry (such as ISO/TS 16949, AEC-Q series standards), and select high-purity, low-resistivity electrolytic copper as raw materials. Specific standards include copper content not less than 99.9%, and mechanical properties such as tensile strength and elongation meet specific specifications to ensure that good conductivity and mechanical strength can be maintained under complex working conditions.
Technical advantages: We use advanced copper wire drawing technology to accurately control the wire diameter tolerance, reduce resistance loss, and improve the stability and efficiency of signal transmission. In addition, for specific application scenarios, such as high temperature environment or high-frequency signal transmission, we can also provide copper wire with special treatments such as tin plating and silver plating to meet higher-level needs.
2. Selection of insulating materials
Standards and requirements: The selection of insulating materials is directly related to the temperature resistance, wear resistance, oil resistance and flame retardancy of the wiring harness. We select materials with excellent high temperature resistance, aging resistance and flame retardancy, such as PVC, TPU, TPE and other polymer materials based on international standards such as UL and RoHS, as well as specific requirements of the automotive industry. These materials must pass strict flame retardant tests (such as UL94 V-0 level), heat aging tests and environmental adaptability tests to ensure that they can maintain stable insulation performance under various extreme conditions.
Technical advantages: We have established long-term cooperative relationships with many internationally renowned material suppliers and introduced new environmentally friendly and high-performance insulating materials. At the same time, advanced extrusion technology is used to precisely control the thickness of the insulation layer, improve the flexibility and durability of the overall wiring harness, and reduce the risk of electrical failures caused by material aging or wear.
Selection and testing of automotive electrical components
1. Selection and testing of relays
Selection and standards: As an important control component in the automotive electrical system, the selection of relays needs to be based on comprehensive considerations such as load type, operating voltage, current, switching frequency and life requirements. We select high-reliability, low-energy consumption and long-life relay products based on international standards such as ISO and SAE and customer needs. Focus on key parameters such as insulation resistance, contact resistance, operating voltage and release voltage.
Test process: Comprehensive performance testing of the selected relays, including durability testing (simulating long-term, high-frequency switching), environmental adaptability testing (such as temperature cycling, humidity changes, vibration shock, etc.) and electromagnetic compatibility testing (EMC) to ensure that they work stably and reliably in complex automotive electrical environments.
2. Selection and testing of sensors
Selection and standards: As an important component for the car to perceive the external environment, the accuracy, response speed and stability of the sensor are crucial. We select sensors with high accuracy, wide measurement range and low hysteresis according to the application scenarios (such as temperature, pressure, speed, position, etc.). At the same time, ensure that the sensors meet international safety standards (such as ISO 26262) and special requirements of the automotive industry.
Testing process: Calibrate and calibrate the sensor to verify the linear relationship and error range between its output signal and physical quantity. Conduct environmental adaptability tests to simulate working conditions under extreme conditions and evaluate its anti-interference ability and long-term stability. In addition, dynamic performance tests are also conducted to ensure that the sensor can respond to external changes quickly and accurately.
3. Selection and testing of switches
Selection and standards: Automotive switches must have good feel, durability and sealing. We select products with moderate operating force, low contact resistance and long electrical life according to the switch type (such as button type, toggle type, rotary type, etc.) and application scenarios. At the same time, pay attention to its waterproof and dustproof level to ensure that it can still work normally in harsh environments.
Testing process: Perform durability tests on switches to simulate frequent operations in actual use and evaluate their electrical life and mechanical durability. Conduct electrical performance tests, including contact resistance, insulation resistance and withstand voltage tests. In addition, environmental adaptability tests are also conducted to verify its sealing and stability under different temperature and humidity conditions.
Our company ensures the quality of raw materials for automotive wiring harnesses and electrical components by strictly implementing the screening, review, incoming material inspection and comparison procedures of raw material suppliers. At the same time, in the selection and testing process of electrical components, we rely on advanced technical means and strict testing standards to ensure that each product can reach the top level of the industry. We are well aware of the importance of precision and quality, so we continue to invest in research and development, optimize production processes, and are committed to providing customers with more reliable and efficient automotive wiring harness and electrical solutions. Choosing us as a partner, you will experience the dual guarantee of quality and performance, and jointly promote the progress and development of the automotive industry.
