What are the types of connection methods for automotive wiring harnesses?

　　The main connection methods for automotive wiring harnesses are as follows, and today the automotive wiring harness manufacturer will introduce them to you.

　　1、 Main connection methods

　　Welding

　　Traditional welding: mainly using tin welding connection, suitable for the assembly of automotive wire harness connections with small batch sizes and cable cross-sectional areas.

　　Ultrasonic welding: In recent years, it has been widely used in the automotive industry, which can achieve lower resistance and higher bonding force, and has advantages over traditional welding methods. Ultrasonic welding does not require additional flux and does not contaminate the structure of the welded parts, ensuring the integrity of the welded parts to the greatest extent possible. However, it should be noted that as the thickness and hardness of the welded workpiece increase, the difficulty of welding will sharply increase, and the required welding power will also be higher.

　　Crimp connection

　　The main method is to apply external force to the corresponding specifications of the compression mold to bond the connector terminals with the cable contact surface. The connection is reliable and has a long service life, suitable for large-scale processing, but requires the use of compression molds to achieve connection assembly. At present, foreign automotive wiring harness cables and connector terminals are generally connected by crimping, and this connection process technology is very stable and reliable.

　　In the crimping of automotive high-voltage wiring harnesses, in order to ensure electrical and mechanical performance, segmented terminals are often used for segmented crimping molding. By crimping the two sections in sequence, the crimping length can be reduced, design space can be saved, and the pull-out force and conductivity requirements of automotive high-voltage wiring harnesses can be met.

　　Mechanical connection

　　The main method is to tightly fix the connector terminals and cables through fasteners, which is relatively complex to assemble and not suitable for mass production.

　　2、 Other connection methods

　　In addition to the three main connection methods mentioned above, car wiring harnesses may also be connected through the following ways:

　　U-shaped connector connection: Wiring harnesses are directly connected through U-shaped connectors.

　　Connector connection: A connector is an electrical module or unit that connects wiring harnesses or electrical appliances, providing a convenient and reliable interface for electrical installation. There are various types of connectors, including plug connectors and socket connectors, which are connected through components such as plug/socket terminals and plug/socket sheaths.

　　3、 Classification of Connection Interface

　　According to the working principle of connection, the connection interface of automotive connectors can be divided into three categories: form lock connection, friction lock connection, and material lock connection. These connection interfaces provide multiple options, including detachable connections (such as plug connections) and non detachable connections (such as double-layer terminal steel card and body connections, welding connections between terminals and wire harnesses).

　　Conclusion

　　In summary, there are various ways to connect automotive wiring harnesses, including welding, crimping, mechanical connections, as well as other methods such as U-joint connections and connector connections. When choosing a connection method, it is necessary to comprehensively consider factors such as specific production needs, wire harness characteristics, and cost-effectiveness.