Causes And Detection Methods Of Electronic Wiring Harness Failure

- Jan 11, 2020-

During the operation of the electronic wiring harness, there are always failures due to various reasons. Common faults include poor connector contact, short circuits between wires, open circuits, grounding, and so on.

So, what are the reasons for the failure of the electronic wiring harness?

1. Natural aging or damage

The use time of the wire harness exceeds the life limit, the insulation layer of the wire harness begins to crack slowly, and the mechanical strength begins to decrease. Over time, it is easy to cause short circuits, disconnections, grounding and other faults between the wires.

2.Wiring harness terminal oxidation

When the wiring harness terminals are completely oxidized or deformed, the wiring harness will have poor contact or short circuit, which will cause the wiring harness to malfunction.

3. Failure of electrical equipment

There is also a situation where the electrical equipment is overloaded and short-circuited, which causes the wiring harness to fail.

4.Human causes

The last cause of the failure was improper human operation, such as the improper installation of the wiring harness, the wiring of the wiring harness and electrical equipment, and the damage to the wiring harness components during maintenance, etc


Detection and discrimination of electronic wiring harness failure:

Grounding: The rule for the burnout of electronic wiring harnesses is that in the circuit of the power supply system, the electronic wiring harness burns wherever it is grounded. If the burnt and the unbroken part meet, you can ground the wire there. When it burns to the wiring part of an electrical equipment, it indicates that the electrical equipment is faulty.


Short circuit: The electronic wiring harness is subjected to external kneading and impact, resulting in damage to the wire insulation layer in the electronic wiring harness, causing a short circuit between the wires, causing some electrical equipment to lose control and the safety wire to blow.


When making the judgment, the electronic harness connector at both ends of the electrical equipment and the control switch can be disassembled, and the short circuit of the circuit can be detected by an electric meter or a test lamp.


Open circuit: In addition to the apparent cracking appearance, rare faults occur between the wires and the wire terminals. After some wires are disconnected, the outer insulation layer and the wire terminals are not missing, but the inner core wires of the wires and the wire terminals have been opened.


When making a judgment, a tensile test may be performed on the high-temperature-resistant wire and the wire terminal of the suspected open circuit. During the tensile test, if the wire insulation layer is gradually thinned, the wire may be admitted to be open. Poor wiring contact, most of the faults occur in the connector.


Poor contact of the connector: When a fault occurs, it will cause the electrical equipment to malfunction.


When making a judgement, turn on the power of the electrical equipment, and touch or pull the relevant connector of the electrical equipment. When a certain connector is touched, the operation of the electrical equipment is normal or abnormal, indicating the connector malfunction