Design of wiring harness for automotive led lighting

The design of automotive led lighting harness, the following automotive automotive wiring harness processing factory editorial :
     Automotive lights are used to provide illumination for automobile driving as well as to signal its driving condition to other vehicles; modern lights, especially headlights, are increasingly playing a decorative role. In order to realize the function of the lights, some lights inside or outside with a small wiring harness, collectively referred to as led lighting harness.
     The electrical principle of led lighting harness is relatively simple, only from a light bulb by a red power cord and a black (or white/black) hitch wire, when several different power bulbs are combined together, the color of the power cord were selected pink, green, etc. The color of the led lighting wire should be selected and the color of the wires in the cabin wiring harness corresponds to the color of the wires.
 First, the external led lighting harness
Integral headlights are often far and near light, steering function and show wide function of the line with a plug connector, automotive wiring harness so that the need to add a led light trim behind the led light trim harness, also known as the external led light trim harness, for this type of wiring harness, the main consideration of waterproof and airtight.
Plug select waterproof series, the material should be nylon or other high temperature resistant materials, plug contact performance of the stability of the vehicle directly affects the exercise of the lighting effect of the lights. Fixed buckle material is generally nylon material. Rubber gasket selection of three yuan ethylene-propylene rubber, gasket precision should be high, and led lighting should be easy to assemble, with can not leak.
Sleeve choose 35 cold rolled plate material, has good ductility; sleeve outer diameter and inner diameter requirements are high, because the sleeve and lamp base is interference fit, after installation of the inner diameter will change, the change is too big will lead to bulb installation difficulties or even can not be installed.
The spring is made of cold-drawn carbon steel wire, the spring force should not be too large, because the combined torque of the lamp head and the glass shell is between 0.3 and 3Nm (please refer to GB/T15766.2-1995 "Performance Requirements for Road Motor Vehicle Lamps" for the specific parameter), and the resistance after assembling is too large, which will lead to the lamp head and the glass shell to be dislodged.
The wires adopt general automobile soft wires can be used. Connection point protection using double wall heat shrink tubing, can prevent oil, water erosion of the connection point. led lighting harness metal parts should be plated to prevent oxidation protection, generally tin or nickel plating.
 Second, the internal led lighting harness
Internal led lighting harness, in addition to considering the requirements of the external led lighting harness, focusing on the front light and the front fog lamp inside up to 120 ℃ temperature requirements.
The back cover can use plastic parts or rubber parts. Plastic parts of the accuracy and stability is better, but the cost is high, generally used for models; rubber parts accuracy and stability is slightly worse, but the cost is low, generally used for low-grade models. Plastic back cover selection of nylon materials, rubber back cover selection of three-dimensional ethylene-pentadiene rubber or silicone rubber. Back cover in the high-temperature environment, airtight performance can not change.
The sheath is made of EPDM rubber or silicone rubber, which cannot be melted or deformed under high temperature.
Wire selection AEXF wire or equivalent temperature resistance requirements of the wire; due to the increase in temperature resistance of the wire, the cross sectional area of the wire with reference to the lower limit value of the external led lighting wiring harness, headlights and front fog lamps can be used in smaller sizes of 0.75mm2 wire. In order to increase the temperature resistance, you can wear the internal wires between the back cover to the sheath with high temperature resistance fiber tube or Teflon sleeve, which can better protect the wires.
Third, HID led lighting harness
HID (HighIntensityDischange) lights is the direction of development of automotive headlights, due to the ballast to 12V voltage instantly increased to 23kV, the normal operation of the voltage is also in the 8kV or so, so the HIDled lighting harness should focus on the consideration of high-voltage security issues. 3 shows.
The design of the plug is the same as the external led lighting harness. The ballast end is generally designed to be fixed, which can better play the role of sealing and connecting. Rubber parts selection of high temperature, high pressure performance of excellent silicone rubber.
Wire selection HID automotive high-voltage wire, this wire using tinned copper conductor, silicone rubber insulation, flexible TPE (thermoplastic elastomer) as the outer sheath, with excellent temperature, pressure, UV resistance and soft performance. Among them, the ballast wiring harness adopts two-core cables, and the bulb wiring harness adopts a single wire for ease of assembly.The power of the HID lamp is generally 35W, and the wire is selected to have a high-voltage nominal cross-section of 0.59mm2.
In order to prevent water mist from entering the cable inside the cable aging, the end of the cable using double-walled heat shrink tubing sealing protection; similarly at the end of the lamp head also use double-walled heat shrink tubing sealing protection.
Fourth, the summary
Led lighting harness design is completed, assembled on the led lighting should meet the requirements of GB10485-89 "automobile and trailer external lighting and signaling devices basic environmental testing" standard.
Special attention should be paid to the general consumers have a misunderstanding: the greater the power of the lights, the brighter the lights. So the modification of the car constantly increase the power of the bulb, resulting in an exponential increase in current and heat, not only to accelerate the led lighting aging and light head melting, but also on the led lighting wiring harness is very harmful. For some special vehicles, the design of led lighting harness should be considered due to the failure caused by the modification.
The above briefly introduces three types of representative led lighting harness, designers can be based on the actual situation of analogies and improvements, flexible application, to achieve the role of one example.

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