EL-22 [Filename: AUTOWIRE.DOC] Automobile Wiring Harness Contributor: Affiliation Address: David H.

Cowling La Tech University Electrical Engineering PO Box 10348 T.S. Ruston, LA 71272 (318) 257-2857 (318) 257-4922 cowling@engr.LaTech.edu Design Project Two to Four Weeks Classroom, Library, Home Summary

June 5, 1997

Phone: Fax: Email: Type: Student Time: Location:

Wiring harnesses for automobiles (or for that matter most mechanically powered vehicles) can be highly complex. There are large numbers of factors that go into their makeup. One must provide for power (i.e., current) for each electrically operated device on the vehicle. However, one must also provide control for each of these electrical devices. Safety also enters because if something goes wrong with any device (or incidentally the wiring harness itself) then current and hence power may climb to destructive levels. This can lead to wires fusing together in the harness, insulation catching fire and ultimately a vehicle fire. Under this design a wiring harness and electrical control system for a vehicle are to be laid out. This should include meeting the requirements of power distribution, total energy distribution, control, and finally safety for a mechanically powered vehicle. This vehicle should be equipped with a reasonable number of amenities (would you actually purchase one of these). This vehicle should also meet the required safety standards (i.e. headlights, taillights, stop lamps, turning signals, windshield wipers, windshield washers, horn, seat belt warning, and other signals and indications both of engine performance and safety.

ABET Descriptors Engr Sci Content: Type: Elements: Features: Constraints: Effort: Electrical, Electrical Power, Electronic Component Establishment of Specifications, Synthesis, Analysis, Evaluation Design Methodology, Creativity, Open-ended, Modern Design Theory Reliability, Cost, Safety, Manufacturability Team

EL-22 [Filename: AUTOWIRE.DOC]

June 5, 1997

Automobile Wiring Harness

Under this project a small design group should layout and design a complete wiring harness for a mechanically powered automobile. This harness should be arranged to power all the features (including the mandated safety features found on an automobile (such as one you would buy). The project should start with a careful examination of the electrical features desired, should continue with a decision on the method of control, followed by a schematic, a wiring diagram and finally the analyzed design of the harness. Wire size, insulation and color code must be specified. Derating of the wire size and insulation should take place based on the method of cabling the harness. The completed design should include but not necessarily be limited to: The electrical specifications for the vehicle. A schematic diagram of the electrical system. A wire routing diagram. The number and routing of the separate sections of the wiring harness. The type of cabling for each of the sections. A specification (wire size, insulation, and color code) for each wire in each section of the wiring harness.

EL-22 [Filename: AUTOWIRE.DOC]

June 5, 1997

Automobile Wiring Harness

Objectives/Comments: This project should cause a team of three or four students to investigate the specifications of the electrical requirements for an automobile. It will require analysis on the students part of the required wire sizes. When cabling is examined wire size may need to be derated. Notice that derating for flat cables would be different from that for round, enclosed cables. This project should also promote some thought on the way to best handle the circuit breaker and fusing requirements for safety. Examples may be made of various US automobile manufacturers versus some of the earlier English (Triumph, MG) manufacturers.

Engineering Notes: The cabling of an automobile may be a weak link. Students will be surprised at the amount of current that is required for simple circuits (for example brake lamps). The wire must be sized in a harness to carry the required current without overheating. If excessive voltage drop occurs electrical devices may work poorly or not at all. The placement of the safety features (circuit breakers, fuses) in a harness is very important. Do not forget the placement fusible links. Some English automobiles (Triumph, MG, Midget, etc.) were built through the 70s without fusible links and the results were disastrous for wiring harnesses in those automobiles. Finally, the students may wish to completely depart from conventional methods of handling the power distribution and the control of the electrical systems. Examples of such departures would be a multiplexed signal bus and a single large power bus. Decoders could be employed to activate the various electrical components from digital codes contained on the signal bus.

Expected Outcomes: Students will become aware of the effort that is required to implement the main electrical circuits of devices that they may think of as mundane. They should develop a new appreciation for the work and effort to design such a system. This is an opportunity to use knowledge that they are acquiring in circuits and apply this to the real world.