Engine wire harness layered wrapping structure

Abstract

The utility model discloses an engine wire harness layered bandaging structure, its characterized in that, including: sensor wire harness group, including the speed sensor line, cylinder temperature / ambient temperature sensor line, oil pressure sensor line, TPS sensor line, accelerator signal line and CAN line, executor wire harness group, including the oil atomizer line, ignition coil line, preheating plug line, rudder machine line, electronic fuel / oil pump line, ECU's VBAT and ground wire and executor power ground wire, first level shielding layer, individually wrapping sensor wire harness group, second level shielding layer, wrapping sensor wire harness group and executor wire harness group together who has wrapped first level shielding layer.

Description

Technical Field

[0001] This utility model relates to the field of aero-engine wiring harness design technology, and in particular to a layered wrapping structure for engine wiring harnesses suitable for high-temperature, high-vibration, and strong electromagnetic interference environments. Background Technology

[0002] In traditional engine wiring harness design, sensor and actuator wiring harnesses are typically bundled together in the same conduit. This design has the following drawbacks: sensor signals are susceptible to high-frequency electromagnetic interference from the actuator, leading to signal distortion; maintenance requires replacing the entire wiring harness, which is costly and inefficient; and the heat generated by the high-power actuator wiring harness can be conducted to the sensor wiring harness, accelerating cable aging. Therefore, a wiring harness structure design that can effectively solve the above problems is needed. Summary of the Invention

[0003] The purpose of this invention is to provide a layered wrapping structure for engine wiring harnesses to solve the problems of signal interference, maintenance difficulties, and poor durability caused by mixed wrapping.

[0004] To achieve the above objectives, the present invention adopts the following technical solution: A layered wrapping structure for engine wiring harnesses includes a sensor wiring harness group, an actuator wiring harness group, a first-level shielding layer, and a second-level shielding layer. The sensor wiring harness group includes various low-signal lines, such as speed sensor lines, cylinder / ambient temperature sensor lines, oil pressure sensor lines, TPS sensor lines, throttle signal lines, and CAN lines. The actuator wiring harness group includes various high-current lines, such as fuel injector lines, ignition coil lines, glow plug lines, servo motor lines, electronic fuel / oil pump lines, ECU VBAT and ground wires, and actuator power ground wires. The first-level shielding layer separately wraps the sensor wiring harness group, and the second-level shielding layer wraps both the shielded sensor wiring harness group and the actuator wiring harness group together.

[0005] Preferably, the first and second shielding layers are made of tin-plated braided mesh or aluminum foil tape, and the two ends of the second shielding layer are provided with waterproof sleeves. The sensor harness and the actuator harness are arranged in parallel.

[0006] During assembly, first thread the sensor harness into the first-level shielding layer and fix it, then arrange it in parallel with the actuator harness, and finally put the whole assembly into the second-level shielding layer and install the waterproof sleeve.

[0007] The beneficial effects of this utility model include: Strong anti-interference capability: The double shielding structure effectively suppresses electromagnetic interference and improves the quality of sensor signals; Easy maintenance: The layered design allows for individual replacement of sensor or actuator wiring harnesses, improving maintenance efficiency; Excellent durability: Insulates heat conduction, enhances wear resistance, tensile strength and corrosion resistance, and extends service life. Attached Figure Description

[0008] Figure 1 This is a cross-sectional view of the wire harness wrapping of this utility model; Reference numerals: 1-Sensor harness assembly; 2-Actuator harness assembly; 3-First-level shielding layer; 4-Second-level shielding layer. Detailed Implementation

[0009] The following is in conjunction with the appendix Figure 1 This utility model will be described in further detail.

[0010] I. Material Preparation Harness grouping: Sensor harness group 1: includes speed sensor wire, cylinder temperature / ambient temperature sensor wire, oil pressure sensor wire, TPS sensor wire, throttle signal wire, and CAN wire. These harnesses are characterized by transmitting weak electrical signals and are susceptible to interference.

[0011] Actuator wiring harness group 2: This group includes injector wires, ignition coil wires, glow plug wires, servo motor wires, electronic fuel / oil pump wires, ECU VBAT and ground wires, and actuator power ground wires. A common characteristic of this type of wiring harness is that it carries a large current, making it a major source of interference.

[0012] Shielding material: The first-level shielding layer 3 and the second-level shielding layer 4 can be made of tin-plated copper braided mesh with good flexibility and high shielding efficiency. It is recommended that the mesh density be no less than 90% coverage to ensure good electromagnetic shielding effect.

[0013] As an alternative, aluminum foil composite tape (such as polyester fiber reinforced aluminum foil tape) can also be used for wrapping, especially suitable for areas with limited space or where weight reduction is required. When using aluminum foil tape, attention should be paid to the overlap coverage, which generally requires the overlap to be no less than 25% of the tape width.

[0014] Auxiliary materials: Waterproof sheath: High temperature resistant, oil resistant, and flexible silicone rubber or heat shrink sheath is used for sealing and protection at both ends of the second-level shielding layer 4.

[0015] Fixing materials: high-temperature resistant cable ties, wire harness brackets or rubber sleeves, used for positioning and fixing the wire harness and shielding layer.

[0016] II. Assembly Steps Primary shielding (first-level shielding) of the sensor harness: Straighten the sorted sensor harness group 1 and slowly thread it into a tin-plated braided mesh tube of appropriate length. The mesh tube should completely cover the section of sensor harness group 1 that needs protection, with at least 20mm left at each end for subsequent fixing or grounding.

[0017] Use a special tool or by hand to tighten the braided mesh tube to fit it snugly against the wire harness. If using aluminum foil tape, wrap it tightly using a half-overlap method (i.e., each wrap overlaps the previous one by half the width), applying tension to ensure a tight wrap.

[0018] The two ends of the first-level shielding layer 3 can be temporarily fixed with high-temperature resistant cable ties or conductive tape to prevent loosening.

[0019] Wire harness assembly and arrangement: Place the sensor harness group 1, which has undergone the first stage of shielding, and the unshielded actuator harness group 2 close together in parallel. During the arrangement, avoid crossing the two types of harnesses as much as possible to reduce potential coupling interference and facilitate differentiation during later maintenance.

[0020] Use cable ties to loosely bundle the two sets of wires together for initial shaping. Be careful not to tighten them too much to avoid damaging the cables or shielding.

[0021] Overall secondary shielding (secondary shielding): The parallel-arranged sensor and actuator harness group 2 is treated as a whole and threaded together into a larger-gauge second-stage tin-plated braided mesh tube. Similarly, if aluminum foil tape is chosen, the entire harness is tightly wrapped.

[0022] The second-level shielding layer 4 should completely cover the end of the first-level shielding layer 3, ensuring there are no shielding gaps.

[0023] Terminal processing and installation: Waterproof sleeves are sequentially fitted onto both ends of the second-level shielding layer 4. The sleeves should be pressed tightly against the outer surface of the shielding layer. If necessary, clamps or adhesives can be used to strengthen the seal, ensuring that moisture and oil cannot penetrate.

[0024] Grounding treatment (optional, depending on EMC requirements): If using tin-plated braided mesh, the first-level shielding layer 3 and the second-level shielding layer 4 can be reliably connected to the ECU's grounding bus or the engine housing grounding point at the end closest to the ECU via a grounding terminal or crimping method to achieve better shielding. If aluminum foil tape is used and grounding is not required, this step can be omitted.

[0025] Finally, use wire clips or brackets to secure the entire wrapped wiring harness assembly to the designated location in the engine compartment, taking care to avoid high-temperature heat sources and moving parts, and leaving an appropriate bending radius.

[0026] III. Precautions Care should be taken during the entire wrapping process to avoid scratching the cable insulation or shielding layer with sharp tools.

[0027] The shielding layer should be grounded with a low impedance connection, and the grounding point should be a clean, highly conductive metal surface.

[0028] This structure is not only applicable to the engine sensor and actuator wiring harnesses, but its layered shielding concept can also be applied to other wiring harness systems with similar strong and weak signals coexisting and requiring interference isolation.

[0029] Through the above specific implementation methods, the layered wrapping structure of this utility model is realized, which effectively improves the anti-interference capability of the wire harness signal, the maintainability of the system, and the durability of the wire harness in harsh environments.

[0030] This specific embodiment is merely an explanation of the utility model and is not intended to limit it. After reading this specification, those skilled in the art can make modifications to this embodiment without contributing any inventive step, but such modifications are protected by patent law as long as they fall within the scope of protection of this utility model.

Claims

1. A layered wrapping structure for engine wiring harnesses, characterized in that, include: The sensor harness assembly (1) includes a speed sensor wire, a cylinder temperature / ambient temperature sensor wire, an oil pressure sensor wire, a TPS sensor wire, a throttle signal wire, and a CAN wire; The actuator wiring harness (2) includes injector wires, ignition coil wires, glow plug wires, servo motor wires, electronic fuel / oil pump wires, ECU VBAT and ground wires, and actuator power ground wires; The first-level shielding layer (3) separately wraps the sensor wiring harness (1); The second-level shielding layer (4) wraps together the sensor harness group (1) and the actuator harness group (2), which are already wrapped by the first-level shielding layer (3).

2. The layered wrapping structure for engine wiring harnesses according to claim 1, characterized in that, The first-level shielding layer (3) and the second-level shielding layer (4) are made of tin-plated braided mesh or aluminum foil tape.

3. The layered wrapping structure for engine wiring harnesses according to claim 1, characterized in that, The second-level shielding layer (4) has waterproof sleeves at both ends.

4. The layered wrapping structure for engine wiring harnesses according to claim 1, characterized in that, The sensor harness group (1) and the actuator harness group (2) are arranged in parallel.

5. The layered wrapping structure for engine wiring harnesses according to claim 1, characterized in that, The structure is suitable for wiring harness arrangement in aircraft engines, motor controllers, or flight control systems.

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