A wiring harness repair method, wiring harness assembly, and vehicle

Abstract

The application discloses a wiring harness maintenance method, a wiring harness assembly and a vehicle, and relates to the field of automobile maintenance. The wiring harness maintenance method comprises the following steps: processing a fault wire; connecting a connector of a power wiring harness and a front wiring harness, which are connected with a pull switch of a starter, by using a cable harness; and fixing the cable harness. The wiring harness assembly is maintained by using the wiring harness maintenance method. The vehicle is maintained by using the wiring harness maintenance method. The application can solve the problem of the pull switch of the starter falling off.

Description

Technical Field

[0001] This invention belongs to the field of automotive repair technology, and specifically relates to a wiring harness repair method, wiring harness assembly, and vehicle. Background Technology

[0002] In automotive aftermarket services, wiring harness systems often require the replacement of entire sections or even entire large wiring harness assemblies due to the failure of a minor component (such as connector terminal pin retraction or poor contact caused by socket enlargement). Such repairs are not only time-consuming and costly, but also fraught with difficulties and complexities in practice. Summary of the Invention

[0003] The purpose of this invention is to provide a wiring harness repair method, wiring harness assembly, and vehicle to solve the technical problem of starter motor pull switch detachment in the prior art.

[0004] The technical solution adopted to solve the above-mentioned technical problems is as follows: This invention discloses a method for repairing wire harnesses, comprising the following steps: Troubleshooting faulty wires; The pull switch of the starter is connected to the connector of the power harness and the front harness using a cable harness; Secure the cable bundle.

[0005] The present invention has at least the following beneficial effects: the wiring harness repair method replaces the faulty wire with a cable harness, realizing the electrical connection between the starter pull switch and the connector of the power wiring harness and the front wiring harness, without replacing the entire power wiring harness or wiring harness assembly, thus saving repair costs; and only the connection between the cable harness and the pull switch and connector is required, reducing repair time, improving repair efficiency, simplifying repair operations, and reducing human error that increases the rework rate due to the replacement of the power wiring harness or wiring harness assembly, such as missing connections, errors, or failure to lock due to the need to disassemble the engine and surrounding components.

[0006] Wiring harness repair requires addressing the faulty wire to prevent it from continuing to conduct electricity and interfering with the normal operation of the wiring harness assembly. It also requires securing the cable harness to prevent it from shifting and affecting its own and surrounding components due to vehicle vibrations.

[0007] As a further improvement to the above technical solution, the faulty wire processing includes the following steps: Cut the faulty wire; Insulate and wrap the two exposed ends of the faulty wire.

[0008] As a further improvement to the above technical solution, the faulty wire processing method further includes the following steps: Secure the faulty wire inside the power harness.

[0009] As a further improvement to the above technical solution, the connector used to connect the starter's pull switch to the power harness and the front harness via a cable harness includes the following steps: Insert one end of the cable bundle into the mating connector between the power harness and the front harness; Connect the other end of the cable bundle to the starter pull switch.

[0010] As a further improvement to the above technical solution, the connector for the connection between the power harness and the front harness includes an S1107E hole, into which one end of the cable harness is inserted.

[0011] As a further improvement to the above technical solution, the fixed cable bundle includes the following steps: Connect the cable bundle to the power harness.

[0012] As a further improvement to the above technical solution, the wire harness maintenance method includes cable ties, and the connection of the cable harness to the power wire harness includes the following steps: Use cable ties to wrap the cable bundles and power wire bundles; Tighten the cable ties.

[0013] As a further improvement to the above technical solution, the cable harness is a short sample of the wire harness.

[0014] This invention discloses a wire harness assembly, which is repaired using any of the wire harness repair methods described in this invention.

[0015] The present invention has at least the following advantages: only the faulty wires in the wire harness assembly need to be replaced using a cable harness, without replacing the entire wire harness assembly, thereby improving maintenance efficiency, simplifying the maintenance process, and saving maintenance costs.

[0016] This invention discloses a vehicle that is repaired using any of the wiring harness repair methods described in this invention.

[0017] The present invention has at least the following beneficial effects: it enables efficient, fast, and cost-effective vehicle wiring harness repair. Attached Figure Description

[0018] The present invention will be further described below with reference to the accompanying drawings and embodiments; Figure 1 This is a flowchart of the wire harness repair method provided in the embodiment of the present invention; Figure 2 yes Figure 1 Detailed flowchart of step S100; Figure 3 yes Figure 1 Detailed flowchart of step S200; Figure 4 yes Figure 1 Detailed flowchart of step S300; Figure 5 yes Figure 4 Detailed flowchart of step S310. Detailed Implementation

[0019] This section will describe in detail specific embodiments of the present invention. Preferred embodiments of the present invention are shown in the accompanying drawings. The purpose of the drawings is to supplement the textual description with graphics, so that people can intuitively and vividly understand each technical feature and overall technical solution of the present invention, but they should not be construed as limiting the scope of protection of the present invention.

[0020] In the description of this invention, it should be understood that the orientation descriptions, such as up, down, front, back, left, right, etc., are based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting this invention.

[0021] In the description of this invention, the use of terms such as "a number" means one or more, with "more than" meaning two or more. Terms like "greater than," "less than," and "exceeding" are understood to exclude the stated number, while terms like "above," "below," and "within" are understood to include the stated number. The use of terms like "first," "second," and "third" is merely for distinguishing technical features and should not be construed as indicating or implying relative importance, the number of indicated technical features, or the sequential relationship between indicated technical features.

[0022] In the description of this invention, unless otherwise explicitly defined, terms such as "set up," "install," and "connect" should be interpreted broadly, and those skilled in the art can reasonably determine the specific meaning of the above terms in this invention in conjunction with the specific content of the technical solution.

[0023] In related technologies, when connector structural designs are flawed, starter motor pull switches frequently detach in multiple vehicle models, necessitating the replacement of the engine wiring harness. Removing the old harness often requires disassembling the engine and other functional components, potentially taking several hours and incurring labor costs far exceeding the value of the harness itself. Furthermore, wiring harnesses are typically located inside the front engine compartment, making it easy for technicians to accidentally damage mating parts when separating connectors and retaining clips. During the installation of new, complex wiring harnesses, there is also the risk of mis-insertion, missed insertion, or incomplete locking of connectors. Any minor operational error can trigger new, more complex malfunctions, requiring the vehicle to be reworked, severely impacting customer experience and damaging brand reputation.

[0024] Reference Figures 1 to 5The following are several embodiments of a wiring harness repair method, a wiring harness assembly, and a vehicle according to the present invention.

[0025] like Figure 1 As shown, the wiring harness repair method of this invention is applied to a wiring harness assembly in a vehicle. The wiring harness repair method includes steps S100, S200 and S300.

[0026] Step S100: Handle the faulty wire.

[0027] In step S100, if the pull switch of some starters repeatedly falls off, arcs, or has poor contact, causing the wire terminals to burn, the copper wires to break, the insulation layer to melt, or even causing ECU signal disorder or the engine malfunction light to illuminate, it indicates that the wiring harness assembly is unreliable. At this time, the wiring harness repair method needs to treat the faulty wires to avoid the faulty wires continuing to interfere with the normal use of the wiring harness assembly after the wiring harness assembly is repaired.

[0028] Step S200: Connect the starter pull switch to the connectors of the power harness and the front harness using the cable harness.

[0029] The starter's pull switch can be electrically reconnected to the connectors of the power harness and front harness via the cable bundle. This allows the pull switch to be energized when the ignition switch is turned to the start position, thus connecting the main circuit between the starter and the connectors of the power harness and front harness.

[0030] Step S300: Secure the cable bundle.

[0031] In step S300, the cable bundle is prevented from shaking or swaying as the vehicle moves or from getting wrapped around other components, which would affect the safety of the cable bundle.

[0032] With this setup, the wiring harness repair method involves using a new cable harness to connect the starter pull switch to the power wiring harness and the front wiring harness. Compared to replacing the entire power wiring harness, using a cable harness to replace the faulty wire for power supply reduces repair costs; reduces repair time and improves repair efficiency, avoiding the complex process of disassembling the engine and surrounding components, resulting in shorter repair times; reduces the complexity and risk of repair operations, as the cable harness only involves localized operations, reducing unnecessary interventions and improving repair reliability; and also avoids derivative faults, ensuring repair quality. Using a cable harness significantly simplifies the operation process, fundamentally reducing the rework rate caused by human errors such as missing, incorrect, or unsecured connectors.

[0033] It is understood that step S100 includes steps S110 and S120, such as... Figure 2 As shown.

[0034] Step S110: Cut the faulty wire.

[0035] In this way, the faulty wire is no longer energized, preventing the wiring harness assembly from becoming unreliable again due to the faulty wire falling off or arcing.

[0036] Step S120: Insulate and wrap the two exposed ends of the faulty wire.

[0037] Because the faulty wire was cut, it has two exposed ends at the cut location. The exposed ends expose the wire inside the insulation layer. If no treatment is done, the exposed wire can easily form a loop when it comes into contact with other components, causing the circuit to be connected and thus affecting the normal operation of the wiring harness assembly.

[0038] In step S120, the two exposed ends of the faulty wire at the cut location are insulated and wrapped to ensure that the wire is no longer exposed at the cut location, making it difficult for the faulty wire to form a loop again, thus ensuring the normal operation of the wiring harness assembly and the vehicle.

[0039] In some embodiments, the two exposed ends of the faulty wire can be wrapped with insulating tape.

[0040] In other embodiments, the two exposed ends of the faulty wire can also be wrapped with flame-retardant tape with insulating properties.

[0041] Furthermore, step S100 also includes step S130, such as... Figure 2 As shown.

[0042] Step S130: Secure the faulty wire inside the power harness.

[0043] Understandably, because the faulty wire was originally in a complete connection state, it was able to remain stable within the wiring harness assembly. When the faulty wire is cut, its two exposed ends break off at the cut point. When the vehicle is in motion, the two ends of the faulty wire at the break point are easily affected by bumps and impacts on nearby wiring harnesses or components, affecting the structural stability of the wiring harness assembly and potentially causing the connection of the faulty wire to loosen.

[0044] In some embodiments, insulating tape or flame-retardant tape is used to adhere the faulty wire to the power harness to prevent the faulty wire from shaking violently when the vehicle is in motion.

[0045] In other embodiments, insulating straps, cable ties, etc. are used to bind the end of the faulty wire near the cut position to the power harness, ensuring that the two ends of the faulty wire at the cut position are fixed relative to the power harness.

[0046] It is understood that step S200 includes steps S210 and S220, such as... Figure 3 As shown.

[0047] Step S210: Insert one end of the cable harness into the mating connector between the power harness and the front harness.

[0048] Step S220: Connect the other end of the cable bundle to the starter pull switch.

[0049] Understandably, the cable harness has terminals at both ends for insertion. One terminal is inserted into the connector between the power harness and the front harness, and the other terminal is inserted into the starter pull switch, thereby realizing the electrical connection between the starter pull switch and the connector between the power harness and the front harness.

[0050] It is understood that the connector for the power harness and the front harness includes an S1107E port, into which one end of the cable harness is inserted.

[0051] Furthermore, the terminal information of the connectors connecting the power harness and the front harness needs to be replaced. Because the portion of the harness connected to the connector between the power harness and the front harness was replaced using a cable harness, the connection position between the starter pull switch and the connector has changed. Therefore, the connector terminal information needs to be replaced to ensure connection reliability.

[0052] With this configuration, the two terminals of the faulty wire can still be inserted into the connectors of the power harness and the front harness, preventing the terminals of the faulty wire from being exposed to humid, high-temperature, or corrosive environments for a long time, which can easily lead to the formation of an oxide layer on the metal surface, increase contact resistance, and affect the burning of the heating rope.

[0053] It is understandable that step S300 includes step S310, such as... Figure 4 As shown.

[0054] Step S310: Connect the cable harness to the power harness.

[0055] This configuration connects the cable bundle to the power harness, allowing the cable bundle to obtain stable support and connection through the power harness. This avoids situations where the cable bundle's movement with the vehicle affects the connection between one terminal and the starter motor pull switch, as well as the connection between the other terminal and the connector of the power harness and the front harness, thus ensuring the stability of the cable bundle.

[0056] In this embodiment, step S310 includes steps S311 and S312, as follows: Figure 5 As shown.

[0057] Step S311: Use cable ties to wrap the cable bundle and power cable bundle.

[0058] Step S312: Tighten the cable ties.

[0059] Understandably, using cable ties to bind and secure the cable harness and power harness makes step S310 simple and cost-effective; the cable ties provide a secure hold, are suitable for long-term use, and do not require frequent replacement; the cable ties can also withstand a certain amount of vibration and mechanical stress, ensuring that the cable harness and power harness can still be stably bound while the vehicle is in motion.

[0060] Understandably, multiple cable ties can be used to perform steps S311 and S312 multiple times to ensure that the cable bundle is connected and fixed to the power cable bundle at multiple locations along the laying direction.

[0061] In some other embodiments, step 310 includes step S313.

[0062] Step S313: Use tape to bind the cable bundle to the power harness.

[0063] Understandably, tape is highly flexible, making it easy to adjust or disassemble temporarily, and convenient for bundling, wrapping, and securing cable bundles and power harnesses.

[0064] In some embodiments, the cable harness may be an existing cable harness with terminals at both ends of appropriate length, the appropriate length of which is selected based on the distance between the starter pull switch and the connectors that mate with the power cable harness and the front cable harness.

[0065] In this embodiment, the cable harness is a short sample. Specifically, a short sample refers to a small number of trial samples made before the formal mass production of a wire harness (such as automotive wire harness, industrial equipment wire harness, etc.) to verify the rationality of the design, the feasibility of the process, and the compatibility of the assembly. Since the short sample is mainly used to test whether key parameters such as wire length, connector matching, wiring path, and assembly space meet the actual needs of the vehicle or equipment, as a cable harness, the short sample can fully ensure that the specifications, types, and locking structures of its terminals are consistent with the original factory specifications. This ensures that the cable harness is compatible with the starter motor's pull switch and the connectors for the power wire harness and the front wire harness, avoiding situations such as poor contact, abnormal signal transmission, or even safety hazards during wire harness maintenance.

[0066] This invention also provides a wiring harness assembly that uses a wiring harness repair method to repair faulty wires. Repairing the wiring harness assembly only requires replacing the faulty wire with a cable harness; it eliminates the need to replace the entire wiring harness assembly or disassemble the engine and surrounding components, thus improving maintenance efficiency.

[0067] In some embodiments, the wiring harness repair method is not limited to repairing faulty wires between the starter pull switch and the connectors of the power wiring harness and the front wiring harness, but can also be applied to other faulty wires in the wiring harness assembly, without specific limitations.

[0068] This invention also provides a vehicle including the wiring harness assembly described above, wherein the wiring harness assembly is repaired using a wiring harness repair method.

[0069] Understandably, the vehicle can be a private car, such as a sedan, SUV, MPV, or pickup truck. It can also be a commercial vehicle, such as a van, bus, small truck, or large semi-trailer. The vehicle must have an electric motor capable of outputting power or acting as a generator to store mechanical energy. When the vehicle is a new energy vehicle, it can be a hybrid or a pure electric vehicle.

[0070] Since the vehicle applies all the technical solutions of the above-described wiring harness repair method, it has at least all the beneficial effects brought about by the technical solutions of the above embodiments, which will not be repeated here.

[0071] The preferred embodiments of the present invention have been described in detail above, but the present invention is not limited to the embodiments described. Those skilled in the art can make various equivalent modifications or substitutions without departing from the spirit of the present invention, and these equivalent modifications or substitutions are all included within the scope defined by the claims of this application.

Claims

1. A method for repairing wire harnesses, characterized in that, Includes the following steps: Troubleshoot the faulty wire; The pull switch of the starter is connected to the connector of the power harness and the front harness using a cable harness; Secure the cable bundle.

2. The wire harness repair method according to claim 1, characterized in that, The faulty wire handling process includes the following steps: Cut the faulty wire; Insulate and wrap the two exposed ends of the faulty wire.

3. The wire harness repair method according to claim 2, characterized in that, The fault-handling method further includes the following steps: Secure the faulty wire inside the power harness.

4. The wire harness repair method according to claim 1, characterized in that, The connector used to connect the starter pull switch to the power harness and the front harness via a cable harness includes the following steps: Insert one end of the cable bundle into the mating connector between the power harness and the front harness; Connect the other end of the cable bundle to the starter pull switch.

5. The wire harness repair method according to claim 4, characterized in that, The connector for mating the power harness and the front harness includes an S1107E port, into which one end of the cable harness is inserted.

6. The wire harness repair method according to claim 1, characterized in that, The fixed cable bundle includes the following steps: Connect the cable bundle to the power harness.

7. The wire harness repair method according to claim 6, characterized in that, Including cable ties, the method of connecting the cable bundle to the power harness includes the following steps: Use cable ties to wrap the cable bundles and power wire bundles; Tighten the cable ties.

8. The wire harness repair method according to claim 1, characterized in that, The cable bundle is a short sample of a wire bundle.

9. A wire harness assembly, characterized in that, The wiring harness assembly is repaired using the wiring harness repair method as described in any one of claims 1 to 8.

10. A vehicle, characterized in that, The vehicle is repaired using the wiring harness repair method as described in any one of claims 1 to 8.

Images