What are the reasons for faults in car wiring harnesses

　　Here are various reasons for the failure of automotive wiring harnesses, which can be mainly summarized as follows:

　　1、 Natural damage

　　Aging and wear: If the service life of the wire harness is too long, the wires will age, the insulation layer will break, and the mechanical strength will significantly decrease. This can cause short circuits, open circuits, grounding and other problems between wires, which may lead to the burning of the wire harness. Meanwhile, the wiring harness will also wear out due to friction during long-term use, especially the wiring harness adjacent to moving parts is more susceptible to damage.

　　Terminal oxidation and deformation: The wiring harness terminals will undergo oxidation and deformation during long-term use, resulting in poor contact and affecting the normal operation of electrical equipment.

　　2、 Electrical malfunction

　　Electrical equipment failure: When electrical equipment experiences overload, short circuit, grounding and other faults, a large amount of heat and current will be generated, which may cause damage to the wire harness. For example, overheating of the engine may cause the insulation layer of the nearby wiring harness to melt, leading to a short circuit.

　　Circuit design issues: Unreasonable circuit design, such as improper wire diameter selection, missing or malfunctioning protective components, may also lead to wiring harness malfunctions during use.

　　3、 Human factors

　　Improper assembly and maintenance: Improper operation during the assembly or maintenance of automotive components, such as metal objects crushing the wiring harness, improper placement of the wiring harness, incorrect connection of electrical equipment leads, and reverse connection of battery positive and negative leads, can all cause damage to the wiring harness.

　　Randomly connecting or cutting wires: When repairing circuit faults, if wires are randomly connected or cut, it not only fails to solve the problem, but may also cause further damage to the wiring harness.

　　4、 Environmental factors

　　Harsh environment: Driving a car in harsh environments such as high temperature, high humidity, and high dust can have adverse effects on the wiring harness. High temperature can accelerate the aging of the wiring harness, while high humidity and dust may cause the insulation layer of the wiring harness to become damp and contaminated, reducing its insulation performance.

　　Vibration and impact: The vibration and impact generated during the driving process of a car can also cause damage to the wiring harness. Long term vibration and impact can cause the fixing device of the wire harness to loosen, and even lead to wire harness breakage.

　　In summary, the causes of faults in automotive wiring harnesses are multifaceted, including natural damage, electrical faults, human factors, and environmental factors. In order to prevent harness failures, it is necessary to regularly inspect and maintain the harness, promptly identify and address potential issues. At the same time, it is necessary to strictly follow the operating procedures during assembly and maintenance to ensure the safety and reliability of the wiring harness.