The tensile strength of automobile control cables is closely related to the way of fixing the wiring harness, and together they determine the stability and safety of the wiring harness during the operation of the vehicle. The following will conduct a detailed analysis from two aspects: tensile strength and the method of fixing the wiring harness, and explain it in combination with the information I have found.

1. automobile control cables tensile strength

The tensile strength of a cable is a key indicator for measuring whether it can maintain structural integrity and functionality when subjected to external forces. According to and, the tensile strength test of the conductor accessory is accomplished by connecting the cable to the connector and applying tensile force at a constant speed. The test speed is usually between 25mm/min and 100mm/min. The specific value should be recorded according to the test report. The selected speed should comply with the standard requirements to ensure the accuracy of the test results.

Furthermore, it is pointed out that the standard tensile strength range of automotive cable ties is from 8kgf to 114kgf, which indicates that there are significant differences in tensile capacity among different types of ties. Therefore, when choosing cable ties, the appropriate tensile strength grade should be determined based on their expected usage environment and load requirements.

Ii. Selection of Wiring harness Fixation Methods

The fixation method of the wiring harness directly affects its direction control, protection effect and tensile strength performance in the vehicle. According to various sources, common wiring harness fixation methods include:

Fixed with cable ties or snap fasteners

Cable ties and clips are among the most commonly used methods for fixing wire harnesses. They can provide a good fixing effect and have a certain tensile strength at the same time. For instance, it is mentioned that the bolt type cable tie is suitable for the wire harness routing with thick or uneven sheet metal, while the steel plate type cable tie is suitable for fixing the edge of sheet metal. Furthermore, it is pointed out that the tensile strength of cable ties is related to their locking mechanism, and LTS (the maximum force that can be applied after the locking mechanism is fixed) is an important parameter for measuring its tensile capacity.

2. Fixed with plastic brackets

When the space for vehicle body structure and wiring harness layout is limited, plastic brackets are an effective fixation method. It is mentioned that plastic brackets are relatively expensive, but they are widely used in models with good sales. It can provide additional protection to prevent the wiring harness from rubbing or wearing against the vehicle body components.

3. Fix it by using the slot structure of other parts

By using existing or newly opened slot structures for wire harness fixation, the reliance on additional fasteners can be reduced. It was pointed out that this method requires marking on the wiring harness to facilitate manufacturing and assembly. At the same time, it is mentioned that T-shaped and L-shaped clips are suitable for situations where the wiring space of the wiring harness is limited due to the installation of exterior decorations.

4. Tape fixation

Although tape fixation is simple, its reliability is relatively low, especially in harsh environments (such as vibration, high temperature, and high humidity), it is not suitable. It should be clearly pointed out that tape fixation is only used in special circumstances and its reliability must be verified through a vehicle durability test.

5. Heavy-duty fixers and cable conduit supports

For wire harnesses with a larger diameter (≥35mm²), heavy-duty fixers are a necessary choice. It is mentioned that heavy-duty fasteners are suitable for fixing large-diameter cables to prevent them from being damaged due to vibration or interference from moving parts. In addition, the cable conduit support can be used to lift the cable from the frame track, separating it from the protruding parts of the vehicle body, thereby preventing wear.

6. Corrugated pipe clamps and sheaths for protection

In areas prone to wear or vibration, bellows clamps and sheaths can provide additional protection. It is mentioned that corrugated tubes can be used to protect the exposed parts of the wiring harness, especially when close to high-temperature areas such as exhaust pipes, closed corrugated tubes should be used to reduce the impact of thermal stress.

Iii. The Synergistic Effect of Tensile Strength and Fixation Method

The tensile strength of the wiring harness not only depends on the material and structure of the cable itself, but is also closely related to the fixing method. For instance, it is pointed out that the tensile strength of cable ties is related to their locking mechanism, and it is mentioned that the material of the snap fasteners (such as PP, PA6, PA66, POM, etc.) also affects their tensile capacity. Therefore, when choosing fasteners, factors such as tensile strength, temperature resistance, water resistance and anti-rotation performance should be comprehensively considered.

Furthermore, it is emphasized that the wiring harness should not remain taut all the time; otherwise, it will continuously exert internal stress on the copper sheets of the wires, accelerating their aging. Therefore, the selection of the fixation method should avoid excessive stretching of the wiring harness while ensuring its stability during vehicle operation.

Iv. Comprehensive Suggestions

In practical applications, the wiring harness fixation method should be selected based on the following principles:

Give priority to choosing commonly used or high-selling snap fasteners or cable ties to simplify material management and reduce costs.

2. In harsh environments (such as high temperature, high humidity, and vibration), high-temperature resistant, waterproof, and anti-rotation fasteners should be selected.

3. In areas prone to wear and tear, bellows, sheaths or heavy-duty fasteners should be used to prevent damage to the wiring harness.

4. At corners and branch points, fixed points should be added to prevent the wire harness from swinging and wearing.

5. Near the connectors, fixed points should be set up to reduce the vibration and the weight of the wiring harness on the terminals inside the connectors.

V. Summary

The tensile strength of automobile control cables is inseparable from the choice of wire harness fixation method. The fixation method not only affects the direction control and protection effect of the wiring harness, but also directly relates to its tensile strength performance. Therefore, when designing and arranging the wiring harness, the cable material, the type of fasteners, the usage environment and the convenience of manufacturing and assembly should be comprehensively considered to ensure the stability and safety of the wiring harness during the operation of the vehicle.