线束设计初步

DelphiConfidential1BasicHarnessDesignBasicHarnessDesign线束设计初步DelphiPackardElectricSystemEJVPEAugust,2003Presenter:ChenShuiHuaDelphiConfidential2Whatmakesagooddesign?Agoodharnessdesignshallbe:Reflectcustomer’srequirementsexactlyandcompletelyQuality:–Noerror–Nodifferentmeaning&Ambiguity–Reliable:10Yearor170,000KMLowcost–AttainCostGoal–VAVEBuildability:–EasytobuildDelphiConfidential3DelphiConfidential4Overview1.SystemPlanview2.StandardCircuitIntroduction3.SchematicsReadingandComprehension4.Layoutdesign5.CableSelection6.Connector,Terminal,SealandPlugselection7.Toleranceanddimension8.HarnessCoveringSelection9.SpliceDesign10.MountingDeviceSelection11.SectionView,TapeBack,HankandNotes,12.ItemandCircuitchartDelphiConfidential5ENGINELampLampLicLp1.TypicalElectricalSystemPlanviewDRCO-DVRDOORREARBODYREARFuelTankENGINEBATTERYINJECTIONTRANSMISSIONINSTRUMENTALFORWARDLAMPBODYMAINDOORDRIVERdomeSTRDelphiConfidential6LampLamp1.TypicalElectricalSystemPlanview(Cont’d)RegionI:-Hot-WetRegionII:-Cool-DryRegionIII:-Cool-WetUsageEnvironmentDelphiConfidential71.TypicalElectricalSystemPlanview(Cont’d)DesignisbasedonUsageEnvironment:HotArea–HighTemperaturecable,likeTXL,AVSX–HighTemperatureConduit,likePP,PA,EPTCoolArea:–LowTemperaturecable,likeTWP,AVSS–LowTemperatureConduit,likePE.WetArea–Sealedconnector–SealedspliceDryArea–Unsealedconnector–UnsealedspliceDelphiConfidential8CircuitStandardizationWheyouseeCKT#140,youcangetfollowinginformationfromESA-610:–TheDescriptionofthiscktis:FUSEOUTPUT-BATTERY-TYPEIIIFUSE–Thisisa“Hotonalltime”circuit–Itistheoutputofaminifuse.–Colorisorange.CircuitstandardizationprovidesacommonengineeringlanguagebtwPackardandcustomerDifferentcustomershavedifferentmethodtostandardizetheirCKTs.ESA-610providesalsostandardDevice2.StandardCircuitIntroductionReftoESA-610DelphiConfidential9CKTSTypeThereareonly5validtypesofofCKTS:–Output–Feed–Ground–Signal–Return2.StandardCircuitIntroduction(Cont’d)ReftoESA-610DelphiConfidential103.SchematicsReadingandComprehensionBeSuretoGetLatestSchematicsFromCustomerBeforeHarnessDesign!DelphiConfidential113.SchematicsReadingandComprehension(Cont’d)Exercise–AddPowerPassengerSeatDelphiConfidential121.Questionoutletswith4ormorebranches–Complicatedboarddesign,congestedboard,difficulttotape,anddifficulttobuild2.Provideproperbranchlengthfromoutlettobackofconnector,–outlet/outlet:»A.1stconnector/outlet:length200mm»B.2ndconnector/outlet:length250mm»C.3rdconnector/outlet:length300mm»Difficulttobuild/tape200mm,boardcongestion.Staggeredlengthsenableeasyholderplacement,lesscongestion,andeasierbuild.3.Commonizesideanddirectionofbranchbreakouts–Easierbuild:easiertotape,applyconduit,andbetterboardlayout.Consistentpluggingdirection.4.Eliminateoutletslessthan100mmapart-evaluatecombiningoutlets–Verydifficulttobuildandtape.Createscongestedboardarea,andmayrequirespecialtoolingandaddedbuildsteps.4.LayoutdesignReftoESA-740and/orDFMhandbookDelphiConfidential135.Commonizeoutletsandbranchlengthsbetweenpartnumbers6.Avoidclosedoutlets–Significantincreasedlaborpenaltyifoutletsaretapedclosed.Useclosedoutletswherecontainment,relativemotion,vibration,abrasion,appearance,orabrasivecontaminants(grit)isanissue-primarilyunderhoodandchassis.7.Eliminateplasticteesandconduitends–Tapingislessexpensive8.Considereliminationofdresscoverstodrivesignificantcostsavings–Containwireswith:vinylspottape(s)–firstchoice–splicetape(s)–secondchoice–wiretie(s)–thirdchoice9.Eliminatelikecolorleadsadjacenttoeachotherinanin-lineconnector–Cancausemis-plugs,andcrossedwires4.Layoutdesign(Cont’d)DelphiConfidential1410.Considererrorproofinglikeconnectorsadjacenttoeachothertoassuretheyarenotmis-plugged–Considerindexingconnectorsdifferently;don’trelyonlyondifferentcolorconnectors11.Minimizethenumberofconnectorswherepossible–Considercombiningtwoormoresmallconnectorswithonelowengageconnector12.Designinoptioncontent–Optioncontentshouldbedesignedforsub-assemblybuildandtoformanyP/Nvariations–withoutchangetothebaseP/Ncircuits,coverings,ordimensions13.Commonizewiregaugesonleadsoutofsplicesiftheyhavesimilarterminalsandlength–Ifsmallergaugeleadispluggedintoacavityrequiringlargegaugeleadthenelectricalproblemsmayresult.Mis-plugscannotbedetectedbyring-outinthissituation.–Commonizingtolargestgaugewillpreventeffectsofmis-plugs.14.Questiontheuseof4ormorewiresintwistedcable–Verydifficultbuildandaddedtoolingexpensetobuild4.Layoutdesign(Cont’d)DelphiConfidential155.CableSelectionCableSAEJISDINTWPTXLSGX:Battery:M1643STX:M3252FusibleLink:M3382R5:M3267M3075M3099M3322M3089M3096GXL:M3101FlexibleSTT:FromGeneratortoStarter:M3391DrainWire:M3098CableSelectionisbasedonthefollowingconsideration:–Schematics–Environmenttemperature–grit–Duty:Heavyorlight–Flexibility–Specialrequirement–CostDelphiConfidential165.CableSelection(cont’d)SAEcableGeneralGuidelineTWPTXLM3096M30890.35SQ0.8SQ1.0SQ0.5SQ2.0SQ3.0SQ5.0SQM3099M30750.35SQ0.8SQ1.0SQ0.5SQ2.0SQ3.0SQ5.0SQCostSaving–7strandsreplaced19strandsQualityImprovement–AnnealedcablereplacesHarddrawnDelphiConfi