Wire harness is an important component used for transmitting electrical energy and signals in electronic devices. The following are the main types of wire harnesses and their application scenarios:

Function

Power harness

Application scenario: Mainly used for transmitting high current and high voltage electricity. In a car, the power harness connects components such as the battery, engine control unit, and generator to provide powerful electrical support for the car's starting, driving, and other functions. For example, the high-voltage wiring harness of a car is used to transmit high voltage and high current between the battery pack and motor controller of a new energy vehicle to drive the motor. Its voltage can reach hundreds of volts and current can reach hundreds of amperes.

Characteristics: Thicker wires are usually used to reduce resistance and minimize energy loss. The insulation layer of the wire also needs to have good heat resistance and aging resistance to cope with the heat generated by high current and long-term use environment.

Signal Harness

Application scenario: Used for transmitting various control signals and data signals. In industrial automation equipment, signal harnesses transmit signals collected by sensors (such as temperature, pressure, position, etc.) to controllers. The controllers issue commands based on these signals to control the actions of actuators (such as motors, solenoid valves, etc.). For example, in a CNC machine tool, the signal harness transmits the pulse signal emitted by the CNC system to the driver, which then controls the precise movement of the motor to achieve the machining operation of the machine tool.

Characteristics: The wires are relatively thin, emphasizing signal integrity and anti-interference ability. Generally, shielding measures such as aluminum foil shielding, braided shielding, etc. are used to prevent external electromagnetic interference from affecting the signal, while reducing the electromagnetic radiation of the signal line itself to the outside world.

Classified by structure

Ordinary wiring harness

Application scenario: Used in some ordinary electronic devices that do not have particularly high performance requirements. For example, the wiring harness inside some small household appliances (such as electric fans, desk lamps, etc.) is mainly used to connect power sources and simple control switches, achieving basic on-off control.

Features: Simple structure, usually composed of several wires wrapped in simple insulation. Low cost and relatively simple production process.

Shielded wiring harness

Application scenario: Widely used in occasions with high requirements for electromagnetic compatibility. In communication base stations, shielded wiring harnesses are used to transmit RF signals, preventing signals from being affected by external electromagnetic interference and generating errors, while also avoiding interference from internal signals of the base station to external communication equipment. In medical equipment such as electrocardiographs and electroencephalographs, shielded wiring harnesses are used to transmit weak bioelectric signals, ensuring accurate signal acquisition and transmission.

Features: It has a shielding layer, which can be made of materials such as metal woven mesh, aluminum foil, etc. After grounding, the shielding layer can effectively block the interference of external electromagnetic fields, while limiting the electromagnetic radiation generated by itself within a certain range, improving the quality and reliability of signal transmission.

Flat wire harness

Application scenario: Very useful in devices with limited space. For example, in some ultra-thin laptops, flat wire harnesses are used to connect the display screen and motherboard. Due to their flat shape, they can adapt well to the compact space structure inside the laptop, reducing the occupation of internal space while maintaining stable signal transmission.

Characteristic: Flat in appearance, usually composed of multiple flat wires arranged side by side. This structure makes the size of the wire harness smaller in the thickness direction, making it easier to route in narrow spaces. Moreover, the heat dissipation performance of flat wire harnesses is relatively good because their larger surface area is conducive to heat dissipation.

Classified by usage environment

Ordinary environment wiring harness

Application scenario: Suitable for general indoor environments, such as wiring harnesses inside ordinary office equipment (printers, copiers, etc.). These devices are typically used in dry, clean, and moderately warm indoor environments, and wiring harnesses do not require special protective measures.

Characteristics: The requirements for insulation materials and protection levels are relatively low, and ordinary insulation materials such as polyethylene and polyvinyl chloride are generally used.

Wiring harness in harsh environments

Application scenarios: Used in harsh environments such as car engine compartments and ship engine compartments. The temperature inside the engine compartment of a car varies greatly, with complex environmental factors such as high temperature, oil pollution, and water vapor. The wiring harness in harsh environments can withstand these harsh conditions, ensuring the normal operation of the automotive electronic control system during engine operation. In the engine room of a ship, the wiring harness needs to resist the corrosion of seawater, oil pollution, as well as high temperature, high humidity and other environments to ensure the stable operation of the ship's navigation, power and other systems.

Features: Using special insulation materials and protective measures. For example, using insulation materials such as high temperature resistant, oil resistant, and water-resistant silicone rubber and fluoroplastics. At the same time, the wiring harness may have additional protective layers, such as waterproof rubber sleeves, anti-corrosion coatings, etc., to improve the durability and reliability of the wiring harness.