071012_线束设计培训

DelphiConfidential1BasicHarnessDesignBasicHarnessDesign线束设计基础DelphiPackardElectricSystemEJVPEAugust,2003Presenter:ChenShuiHuaDelphiConfidential2Whatmakesagooddesign?Agoodharnessdesignshallbe一个好的线束设计应包含如下:Reflectcustomer’srequirementsexactlyandcompletely充分准确的反映客户的要求.Quality质量要求:–Noerror无错误.–Nodifferentmeaning&Ambiguity无歧义.–Reliable:10Yearor170,000KM可靠性为10年或17万公里.Lowcost低成本–AttainCostGoal考虑成本要求.–VAVE价值工程分析–EC4成本节余Buildability:可操作性–Easytobuild便于制造.DelphiConfidential3Overview1.SystemPlanview系统拓普图2.StandardCircuitIntroduction标准电路3.SchematicsReadingandComprehension电路图识读4.Layoutdesign线束布局5.CableSelectionAndcircuitprofection导线选择6.Connector,Terminal,SealandPlugselection插接器,端子,密封,盲栓选取7.Toleranceanddimension尺寸公差8.HarnessCoveringSelection覆盖物选取9.SpliceDesign焊接设计10.MountingDeviceSelection固定件选取11.SectionView,TapeBack,HankandNotes,零件图12.Itemandwirechart材料明细DelphiConfidential4ENGINELampLampLicLp1.TypicalElectricalSystemPlanviewDRCO-DVRDOORREARBODYREARFuelTankENGINEBATTERYINJECTIONTRANSMISSIONINSTRUMENTALFORWARDLAMPBODYMAINDOORDRIVERdomeSTRDelphiConfidential5EngineFuelTankMDLLampMDLLampLpSMLpSMSTARTERGeneratorBATTIMMOGND1GND22.5/2.56.0GND3GND1:ABSCONTR.UNITGND2:SIDEBLINKER-1.0x2KPA/C-2.5CE-6.0HEADLP-1.5FOGLP-1.0TURNSIGNAL-1.0x2GND3:ROOMLGT-0.5GEARRANKINGINDICATOR-0.5CENTR-LOCKLEFT-1.0POWERWINDOW-0.35x4CENTR-LOCKECU-2.5ELE-MIRROR-0.356.00.5GND4:OILTANKSNSR-0.5GND5:NUMBERPLATELGT-1.0x2BOOTLGT-0.5READINGLGT-0.5x2(OPTION)2.5GND4GND5GND6GND6:3rdBRAKELGT-1.0TAILLGT-1.0x2ENGINEW/HBODYW/HPRE-ENGINEW/HHEADLIGHTW/H2.5/2.5GND7:ECMCONTROL-2.5/2.5GND7GENERATORW/HGND8GND8:MAGNETCOUPLE-0.5(PRE-ENG.)MOTORCONTROL-1.0(PRE-ENG.)RUV4-1.5(PRE-ENG.)HT-RESISTANCE-0.5(PRE-ENG.)COOLINGFAN-4.0IMBOCONTR.UNIT-1.0x2IPW/HSTEERINGW/HA/CCONTROLBOXWIPERMOTORCENTRALLOCKECU6.01.5GND90.5GND9:ECM-0.51.TypicalElectricalSystemPlanviewDelphiConfidential6LampLamp1.TypicalElectricalSystemPlanview(Cont’d)RegionI:-Hot-WetRegionII:-Cool-DryRegionIII:-Cool-WetUsageEnvironmentDelphiConfidential71.TypicalElectricalSystemPlanview(Cont’d)DesignisbasedonUsageEnvironment:HotArea高温区域–HighTemperaturecable,likeTXL,AVSX–HighTemperatureConduit,likePP,PA,EPTCoolArea低温区域–LowTemperaturecable,likeTWP,AVSS–LowTemperatureConduit,likePE.WetArea湿区–Sealedconnector–SealedspliceDryArea干区–Unsealedconnector–UnsealedspliceDelphiConfidential81.TypicalElectricalSystemPlanview(Cont’d)门线束的特别之处:门钢板线束部分:湿区域门钢板内饰线束部分:干区域DelphiConfidential9CircuitStandardizationWheyouseeCKT#140,youcangetfollowinginformationfromESA-610:–TheDescriptionofthiscktis:FUSEOUTPUT-BATTERY-TYPEIIIFUSE–Thisisa“Hotonalltime”circuit.–Itistheoutputofaminifuse.–Colorisorange.CircuitstandardizationprovidesacommonengineeringlanguagebtwPackardandcustomerDifferentcustomershavedifferentmethodtostandardizetheirCKTs.ESA-610providesalsostandardDevice2.StandardCircuitIntroductionReftoESA-610DelphiConfidential102.StandardCircuitIntroduction(Cont’d)ReftoESA-610DelphiConfidential113.SchematicsReadingandComprehensionBeSuretoGetLatestSchematicsFromCustomerBeforeHarnessDesign!DelphiConfidential124.Layoutdesign(Cont’d)DelphiConfidential131.Questionoutletswith4ormorebranches公共节点分支不能超过4个.–Complicatedboarddesign,congestedboard,difficulttotape,anddifficulttobuild复杂的案板设计,缠绕困难,操作困难.2.Provideproperbranchlengthfromoutlettobackofconnector从节点到插接器末端的分支长度:–outlet/outlet:»A.1stconnector/outlet:length200mm.第一个分支长度200mm.»B.2ndconnector/outlet:length250mm.第一个分支长度200mm.»C.3rdconnector/outlet:length300mm.第一个分支长度200mm.»Difficulttobuild/tape200mm,boardcongestion.Staggeredlengthsenableeasyholderplacement,lesscongestion,andeasierbuild.分支长度200mm制作困难,长度错开尽可能的达到holder容易摆放,低密度,容易制作.3.Communizesideanddirectionofbranchbreakouts对于节点相同伸出方向不同的分支:–Easierbuild:easiertotape,applyconduit,andbetterboardlayout.Consistentpluggingdirection.4.Eliminateoutletslessthan100mmapart-evaluatecombiningoutlets尽量减少分支节点间尺寸低于100mm的布置。–Verydifficulttobuildandtape.Createscongestedboardarea,andmayrequirespecialtoolingandaddedbuildsteps.4.LayoutdesignReftoESA-740and/orDFMhandbookDelphiConfidential145.Communizeoutletsandbranchlengthsbetweenpartnumbers。6.Avoidclosedoutlets尽量减少封闭式节点–Significantincreasedlaborpenaltyifoutletsaretapedclosed.Useclosedoutletswherecontainment,relativemotion,vibration,abrasion,appearance,orabrasivecontaminants(grit)isanissue-primarilyunderhoodandchassis.7.Eliminateplasticteesandconduitends取消T型塑件和波纹管管夹.–Tapingislessexpensive8.Considereliminationofdresscoverstodrivesignificantcostsavings考虑减少表面覆盖物的使用数量–Containwireswith:vinylspottape(s)–firstchoice–splicetape(s)–secondchoice–wiretie(s)–thirdchoice9.Eliminatelikecolorleadsadjacenttoeachotherinanin-lineconnector避免在同一个连接件内出现颜色相近的导线.–Cancausemis-plugs,andcrossedwires4.Layoutdesign(Cont’d)DelphiConfidential1510.Considererrorproofinglikeconnectorsadjacenttoeachothertoassuretheyarenotmis-plugged避免在相邻位置上使用类似的插接器,以防止插接错误–Considerindexingconnectorsdifferently;don’trelyonlyondifferentcolorconnectors11.Minimizethenumberofconnectorswherepossible尽可能减少插接器的零件种类.–Considercombiningtwoormoresmallconnectorswithonelowengage