The common causes of wire harness faults mainly include the following aspects:
1. Natural factors
Aging: If the wiring harness is used for too long, the insulation layer of the wire will gradually age and break, and the mechanical strength will decrease, which can easily lead to short circuits, open circuits, or grounding between wires
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Oxidation: The oxidation and deformation of wire harness terminals result in poor contact and affect the normal operation of electrical equipment
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Environmental factors: Damp, rainy, or high-temperature environments may cause damage to the insulation layer of the wiring harness, corrosion of the wires, increased resistance, and even interruption of signal transmission
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2. Human factors
Improper installation or maintenance: During assembly or maintenance, improper operation may result in damage to the insulation layer of the wiring harness, improper positioning or incorrect connection of the wiring harness, and even random wiring or cutting of wires
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Mechanical damage: Metal objects may crush the wiring harness, causing insulation layer rupture or wire damage
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3. Equipment malfunction
Electrical equipment malfunction: When electrical equipment experiences overload, short circuit, or grounding issues, it may damage the wiring harness
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Connector failure: The connector may experience failure modes such as terminal retraction, misalignment, and virtual connection, resulting in poor contact or signal interruption
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4. Quality issues with wiring harnesses
Manufacturing defects: During the manufacturing process of wire harnesses, there may be problems such as unreasonable design, short branches, or non-standard manufacturing, which can easily damage the wire harness
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Material issue: The insulation material of the wiring harness is of poor quality and may not be able to withstand high temperatures, humidity, or mechanical stress
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5. External factors
Mechanical wear: The wiring harness may experience insulation layer wear or wire breakage due to frequent vibration, friction, or excessive bending during use
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External impact: The wiring harness may be damaged by external collision or compression, which may cause insulation layer damage or wire short circuit