线束设计规范

2009—06—20发布2009—06—20实施北汽福田汽车股份有限公司发布线束设计规范编制：刘震审核：徐梅批准：叶树珩线束设计规范I目录一、接插件的规划与选择··································································································1（一）接插件的规划··································································································1（二）接插件的选择··································································································21、接插件的种类····················································································22、护套选取原则····················································································73、端子选取原则·····················································································94、线间接插件的选择·············································································105、与用电设备接插件的选择···································································10二、线束防护固定与安装·····································································································11（一）、线束的防护································································································111、波纹管··································································································112、PVC管·································································································113、胶带······································································································124、橡胶件··································································································12（二）、线束的固定与安装·························································································13（三）、线束布置、包扎的注意事项···········································································16三、导线的选型与规划··········································································································16（一）、导线的类型·····································································································161、导线的种类······························································································162、各种导线的名称及工作温度·····································································18（二）、导线的选型······································································································221、导线类型选择···························································································222、导线颜色选线束设计规范II择···························································································233、导线选择的其他注意事项·········································································23线束设计规范1线束设计规范一、接插件规划与选择（一）、接插件的规划1、首先需要根据开发车型的用电器布置情况，规划出车型的整车线束大体布置图，其次根据车型配置将布置图尽量细化到用电器，此时暂可不考虑用电器的具体位置，只要区分出大体位置，即机舱、车门、前地板等区域即可。见附图1。2、依据上面的布置图、车型的配置表，以及各用电设备的具体参数、原理估算出各条线束间对接的分支回路数目。见附表1附图1整车线束布置示意图附表1线束间对接的分支回路统计表（根据各车型实际情况增减）序号插座插头实际需求针脚数车身过孔尺寸接插件数量是否需防水备注线束名称线束名称线束设计规范21司机门线束总成、前围仪表线束总成车身板金；车门板金2副司机门线束总成前围仪表线束总成车身板金；车门板金3左后门线束总成地板线束总成车身板金；车门板金4右后门线束总成地板线束总成车身板金；车门板金5后背门线束总成地板线束总成车身板金；后背门板金6后保险杠线束总成地板线束总成7车架线束总成地板线束总成8前围仪表线束总成地板线束总成9发动机仓线束总成前围仪表线束总成10蓄电池线束总成发动机仓线束总成11顶棚线束总成前围仪表线束总成（二）、接插件的选择1、接插件的种类1）、常见的接插件厂家标识厂家护套标识厂家护套标识住友（SWS）失崎（YAZAKI）JAEKET线束设计规范3TYCO（AMP）德尔福（DELPHI）MOLEX古河(FURUKAWA）FCI鹤壁天海（THB）余姚电器二厂南通友星白城派克丰迪2）、接插件的结构形式①、防水接插件要达到防水、防尘的效果。一般可分为整体密封和单孔密封，后者较为常用；采用的密封材料可为：橡胶密封塞和注胶密封，前者较为常用。整体式密封线束设计规范4②、带挂接机构的接插件，优点是使接插件的固定更为方便，避免了接插件无固定而产生噪音，使连接更可靠。可分为直接挂接和卡扣挂接两种。卡扣挂接中的卡扣又分以下几种：单孔式密封直接挂接卡扣挂接线束设计规范5a、护套本身自带卡扣b、护套本身有挂接位置，可以外挂卡扣，外挂卡扣一般分为以下几种：注：选用卡扣时，还要考虑卡扣所适合的钣金厚度。卡扣类型车身开孔尺寸C、护套之间可以相互挂接线束设计规范6③、带卡锁机构的接插件，其优点是使线与线间或线与电气件间的连接更为牢固，防止松动。一般用在发动机上、雨刮电机等颠簸震动的环境。卡锁机构形式的插接件一般有如下几种。a、b、护套顶部与下部相互挂接护套本身自带锁片线束设计规范7C、d、④、带压线盖的接插件，它可保证插接件插入的端子尾部压接的导线不在插接件根部时出现不必要的晃动，减少插接件震动对导线的剪切力，提高线束的品质锁片插接在护套尾部锁片插接在护套尾部锁片插接在护套前部线束设计规范82、护套选取原则：①、护套选取要保证与电器件的良好接触，使接触电阻降为最低，提高可靠性，优先选用双弹簧式压紧结构的插接件。②、根据导线的截面积和通过电流的大小合理选择护套的尺寸。③、在发动机舱、底盘等较恶劣的环境下对接的护套，由于温度、湿度偏大且存在着很多腐蚀性气体和液体，因此一定要选择防水性护套，其空位需用防水堵密封。同时还应注意护套材质的选择，如阻燃等性能。④、避免在同一对接区域使用同一种护套，若无法避免，则需通过不同颜色加以区分。⑤、基于汽车外观的整体协调性，在发动机舱中应优先选用黑色或深色的护套。⑥、为减少线束对接用护套的种类和数量，优先选用混合型件，使装配固定方便，见下图。⑦、车门线束与车身线束对接时，其最好选用带卡锁机构的护套，保证在车门频繁的开闭中，避免出现对接松脱现象。4.8型端子2.8型端子线束设计规范9⑧、为节约成本，安全等级较低的用电设备尽量选择满足其性能要求的国产件；驾驶室内除地板外可选择非防水型护套；在不同区域采用同种型号的护套，减少品种。⑨、离发动机舱高温部位的插接件应选用耐高温材料的护套。⑩、根据不同的需求选择不同材质的护套（各种材质的具体性能差异见附表），可根据实际情况在塑料中添加阻燃或增强材料，以达到增强或阻燃的目的，如添加玻璃纤维增强等。附表：接插件护套材质的性能差异3、端子选取原则插接件用的端子主要是由黄铜和青铜构成（黄铜的硬度比青铜的硬度稍低），其中黄铜占的比重较大。另外，可根据不同的需求选择不同的镀层。对于要求性能较高的安全气囊、ABS、ECU等用的端子插接件，应优先选用镀金件以保证安全可靠性，但出于成本考虑，在满足性能要求的前提下可选择局部镀金处理。①、保证端子与所选的插接件的合理匹配；②、针对所压接电线的线径选择合适的端子；③、对于单孔防水插接件，要选择尾部能压接防水栓的端子；线束设计规范10④、端子要优先选择接触电阻非常小的双弹簧式的结构；⑤、日系端子过流额度（仅供参考）防水型：型号040050055060070090110187250312375承载电流3A3-5A3A6A9A10A10A20A20A42A60A适用线径0.3-0.850.3-0.850.50.3-0.850.3-2.00.3-2.00.3-2.00.3-3.00.5-3.00.5-8.03.0-8.0非防水型：型号030050060070090110187250312375承载电流3A3A6A9A10A10-15A20A20-25A42A60A适用线径0.3-0.50.3-0.50.3-0.850.3-2.00.3-2.00.3-2.00.3-3.00.3-3.00.5-8.03.0-8.0⑥、国产端子过流额度（仅供参考）系列12.2、34.86.37.8、9.5承载电流(A)10203045604、线间接插件的选择根据附表1以及上述的接插件选择原则，对线间接插件进行选型。见附表2。其中需要注意的是，每条线束的接插件均需要至少预留2至3个空脚位便于功能扩展。5、与用电设备接插件的选择①、要求线束端（A端）与用电器端（B端）的接插件必须采用同一供应商、同一对接型号的产品。②、若B端为固定端，则需要对A、B端的连接进行试验验证，编入线束