If the shielding layer of the wire harness is damaged, it can be safely reused by following the "three-step method":

Immediately cut off power

First, cut off the power supply (or unplug the negative terminal of the battery) to prevent electric shock or EMI leakage caused by exposed high-voltage/signal lines.

Assess the extent of damage

• Small area: Only the outer aluminum foil or woven mesh is partially torn, with no exposed conductor → repairable;

• Large area: If the shielding layer is missing by more than 30% or the insulation layer is damaged, it is recommended to replace the entire section to avoid signal crosstalk or short circuit.

On-site repair method

A. Cleaning: Wipe the break with alcohol cotton to remove oil stains and oxide layer.

B. Supplement the network:

- Aluminum foil damage: Wrap the damaged area with 0.05 mm conductive aluminum foil tape, overlapping it ≥2 layers, and ensure the overlap with the original shielding layer is ≥10 mm.

- Damaged braided mesh: Apply a copper braided mesh cover (≥95% coverage) and secure both ends with copper crimping rings.

C. Grounding restoration: Weld or crimp the shielding layer of the repaired section to the original grounding wire to ensure overall conductivity <0.1 Ω.

D. Insulation reinforcement: Apply a heat-shrinkable tube (with adhesive) over the outer layer and heat it to shrink, restoring IP67 protection.

verify

• Use a multimeter to test the continuity of the shielding layer;

• Check the shielding effectiveness using an oscilloscope or network analyzer to ensure it is ≥60 dB@1 GHz. If it meets the requirement, it can be put back online