Evaluating the reliability of wiring harnesses requires testing and validation from multiple perspectives. The following is based on the latest assessment that the reliability of the wiring harness is key to ensuring its long-term stable operation in various application scenarios. The following are detailed evaluation methods and steps:

1. Appearance inspection

Inspection content: Check the appearance of the wiring harness to ensure that there is no obvious damage, wear, cracking, or aging. Special attention should be paid to the bent parts and joints of the wiring harness, as these areas are prone to fatigue and wear.

Tools: Visual inspection or use a magnifying glass.

Frequency: It is recommended to conduct a comprehensive inspection every 40000 kilometers.

2. Electrical performance testing

Continuity test:

Purpose: To ensure good conductivity of the wiring harness without short circuits or open circuits.

Method: Use a multimeter or continuity tester to measure the voltage and current at the wire harness endpoints and calculate the resistance value.

Tools: multimeter, continuity tester.

Frequency: It is recommended to conduct a comprehensive conductivity test once a year.

Insulation resistance test:

Purpose: To ensure good insulation performance of the wiring harness and avoid leakage or short circuit.

Method: Use an insulation resistance tester, apply high voltage, and measure the insulation resistance between the wires of the wiring harness.

Tool: Insulation resistance tester.

Frequency: It is recommended to conduct an insulation resistance test once a year.

Voltage withstand test:

Purpose: To ensure the insulation performance of the wiring harness under high voltage.

Method: Apply high voltage to the wire harness for a certain period of time, measure the current on the wire harness, and determine whether it exceeds the set value.

Tool: Voltage tester.

Frequency: It is recommended to conduct a voltage withstand test every two years.

3. Mechanical performance testing

Tensile testing:

Purpose: To evaluate the performance of wire harnesses under mechanical stress.

Method: Use a tensile tester to apply tension to the wire harness and record its fracture strength.

Tool: Tensile testing instrument.

Frequency: Depending on the usage environment, it is recommended to conduct a tensile test every two years.

Bending test:

Purpose: To evaluate the durability of wiring harnesses under frequent bending.

Method: Use a bending tester to perform bending tests on the wire harness at a specified angle and complete the specified number of bends.

Tool: Bending tester.

Frequency: According to the usage environment, it is recommended to conduct a bending test every two years.

4. Environmental adaptability testing

High temperature test:

Purpose: To evaluate the performance of wire harnesses in high temperature environments.

Method: Place the wiring harness in a high-temperature environment box, maintain it for a certain period of time, and observe its performance changes.

Tool: High temperature environmental chamber.

Frequency: Based on the usage environment, it is recommended to conduct a high temperature test every two years.

Low temperature test:

Purpose: To evaluate the performance of wire harnesses in low-temperature environments.

Method: Place the wiring harness in a low-temperature environment box, maintain it for a certain period of time, and test its flexibility and electrical performance.

Tool: Low temperature environmental chamber.

Frequency: Based on the usage environment, it is recommended to conduct a low-temperature test every two years.

Damp heat test:

Purpose: To evaluate the performance of wiring harnesses in humid environments.

Method: Place the wiring harness in a high humidity environment, maintain it for a certain period of time, and test its performance.

Tool: Damp heat testing chamber.

Frequency: Depending on the usage environment, it is recommended to conduct a humidity test every two years.

5. Electromagnetic compatibility (EMC) testing

Radiation emission test:

Purpose: To evaluate the radiation level of the wiring harness during operation.

Method: Measure the radiation level of the wiring harness during operation through an antenna.

Tool: Electromagnetic interference tester.

Frequency: It is recommended to conduct a radiation emission test once a year.

Radiation immunity test:

Purpose: To evaluate the performance of wire harnesses under electromagnetic interference.

Method: Check the working performance of the wiring harness under electromagnetic interference.

Tool: Electromagnetic interference tester.

Frequency: It is recommended to conduct a radiation immunity test once a year.

6. Durability testing

Mechanical fatigue testing:

Purpose: To evaluate the durability of wire harnesses under mechanical stress.

Method: Apply mechanical stress to the wire harness, such as vibration, bending, twisting, etc., and record its durability.

Tools: vibration testing bench, bending tester.

Frequency: Based on the usage environment, it is recommended to conduct durability testing every two years.

7. Record and maintenance plan

record:

Content: Record the time and content of each inspection, cleaning, and replacement. This helps track the usage status of the wiring harness and promptly identify potential issues.

Tool: Notebook or spreadsheet.

Frequency: Record after each inspection.

Maintenance plan:

Content: Develop a detailed maintenance plan to ensure that the maintenance work of the wiring harness can be carried out on time, avoiding equipment failures or safety accidents caused by negligence.

Tool: Maintenance Schedule.

Frequency: Based on the usage environment, it is recommended to develop a maintenance plan every six months.