How to optimize the thread structure of automotive wiring harness dustproof threaded silicone sheath to adapt to the complex wiring harness layout of different wire diameters and multiple branches?

Publish Time: 2024-12-17

In the highly integrated and sophisticated mechanical "jungle" of automobiles, the wiring harness is like a crisscrossing neural network, connecting various key components. The automotive wiring harness dustproof threaded silicone sheath is responsible for protecting these "nerve veins" from dust and maintaining the stability of the electrical system. Faced with complex and changeable wire diameters and maze-like multi-branch wiring harness layouts, optimizing its thread structure has become a key breakthrough point to improve protection performance and installation convenience.

Starting from the demand for fast sleeve insertion, the variable pitch thread design stands out. Although the traditional equidistant thread is easy to process, it is easy to get stuck when threading the sleeve when facing the wiring harnesses of different thicknesses. The variable pitch thread can adopt a large pitch at the entrance, just like widening the river mouth, so that the thick wire harness can be smoothly introduced and the initial friction can be reduced; as the sheath goes deeper, the pitch gradually narrows, closely fitting the wire harness, cleverly adapting to the decreasing trend of the wire diameter, laying the foundation for the precise positioning of the subsequent branches, just like customizing a unique "track" for each section of the wire harness, so that the sleeve insertion action can be completed in one go, greatly reducing the installation time.

In order to take into account the tightening and sealing, the improvement of the cross-sectional shape of the thread cannot be ignored. The traditional triangular thread is optimized into a composite structure with an arc-shaped thread bottom and a trapezoidal side. The arc-shaped bottom surface is like a gentle palm, gently wrapping the wire harness to avoid scratching the insulation layer and providing stable support; the trapezoidal side is like a solid barrier. When rotating and tightening, the bite force between adjacent thread teeth is stronger, and the pressure is evenly dispersed. Even if the vehicle is bumpy and vibrating, it can firmly lock the position, tightly block the dust invasion path, and ensure that the gap at the branch is impeccable.

For the problem of multiple branches, the branch point connection thread is the focus of innovation. The forked thread design is introduced. Before the wiring harness branches, the thread is cleverly fissioned in a "Y" or "T" shape. Each branch corresponds to an independent thread branch system, each accurately matches the outer diameter of the branch harness, which not only maintains the sealing continuity of the main harness, but also provides independent fastening protection for the branch line, just like customizing a fitting "armor" for each member of the harness family. During assembly, workers can quickly find the docking point according to the branch layout to eliminate the hidden dangers of wrong set and missing set.

Automotive wiring harness dustproof threaded silicone sheath The coordinated upgrade of materials and threads is also critical. The high elasticity and low friction coefficient silicone formula is selected to allow the thread to have "elastic buffer" when it deforms to adapt to different wire diameters, and the set is smooth and unobstructed instantly; nano-level wear-resistant particles are filled to enhance the wear resistance of the thread, withstand long-term wear and tear, and still maintain the protection position after the entire life cycle of the car. With the help of 3D modeling and simulation software, virtual testing of threading force and sealing pressure distribution under different optimization schemes is carried out. Combined with repeated verification and adjustment on the actual vehicle, a threaded structure that best suits the complex "wiring harness ecology" of the car is crafted, and the exquisite design is used to safeguard the safety and stability of the car's electrical system.