The automobile wiring harness is the network main body of the automobile circuit. Without the wiring harness, there would be no automobile circuit.The material of automobile wiring harness is different from that of ordinary household wiring harness. It is usually composed of several or even dozens of soft copper wires wrapped in plastic insulating tubes. The internal wire core is as soft as hair, but not easy to break.This kind of wiring harness has very high requirements for air tightness during use. If its air tightness is not good, it is easy to leak electricity during use and cause car failure.To ensure safety, manufacturers will conduct air tightness testing on automobile wiring harnesses during the production and assembly process. However, due to the various types of automobile wiring harnesses, the methods for testing them are also different.    

As an expert in the production of automotive wiring harness air tightness testers, Hairis Technology has also done in-depth research on the detection of automotive wiring harnesses and has achieved good results.So, this time we will share a case of air tightness testing of automobile wiring harness for your reference.

1. Display of the appearance and detection difficulties of automobile wiring harnesses

1. Automotive wiring harnesses are mainly composed of copper connectors (plugs, sockets), plastic sheaths, and wires. The connectors and wires are crimped and installed in the plastic sheath. The wires are bundled with wire harnesses and wrapped with tape;

2. This car wiring harness has two connector sets with long and thick wires. The two butt sets are connected by wires wrapped in plastic sheaths;

3. Due to the length of the automobile wiring harness and the shape of the double connector, it cannot be fixed well during inspection. Moreover, the wiring harness is highly soft, has long wires, and is easy to fold, making it difficult to directly inspect the whole;

4. In order to achieve its sealing, the manufacturer uses a sealing ring and overall glue filling at the joint to isolate the intrusion of external substances. The leakage value is small and it is difficult to monitor the data.

2. Breakthroughs in difficult air tightness testing of automotive wiring harnesses and demonstration of the testing process

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Hairis Technology Automotive Wiring Harness Air Tightness Detector

 1. Since the two butt joints of the wire harness are connected to the hollow plastic wire, Hairis Technology customized a mold tooling according to the condition of the automobile wire harness. It can snap the connectors on both sides of the wire harness into the mold. In order to better fix the connectors at both ends of the wire, a groove is specially made so that the top and bottom of the mold can be better sealed when closed.

2. Put both ends of the wire harness into the tooling mold and connect it to our instrument. There is a valve island, gas tank and other components inside the instrument as well as the program we have set. After the connection is made, press the start button when testing the wire.At this time, the upper and lower molds begin to close, and clean gas without impurities is filled into the inside of the automobile wiring harness. The instrument display screen will judge the sealing degree of the sight through the gas saturation inside the sight.

3. If the automobile wiring harness is not sealed and air leakage occurs, the leakage value displayed in the instrument will become larger and larger, and the pressure value will decrease at the same time.At this time, it can be determined whether the automobile wiring harness is leaking, and the instrument test result will also show NG, which means the air tightness test failed.If the tested automobile wiring harness does not leak, the gas in the tooling mold will be in a constant state after inflation. The pressure value and leakage value displayed on the instrument are also stable. The instrument test result will display OK, indicating that the air tightness test has passed.

Hairis Technology Automotive Wiring Harness Air Tightness Testing Demonstration

3. Parameter table of automobile wiring harness air tightness detector

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