The bending radius of the wiring harness refers to the radius of the arc that the cable in the automotive wiring harness is allowed to form when it is bent. Its standard value is usually 5 times the outer diameter of the cable.
The bending radius of the wiring harness refers to the radius of the arc that the cable in the automotive wiring harness is allowed to form when it is bent. Its standard value is usually 5 times the outer diameter of the cable. The following is a specific description:
Definition and Measurement Method
1) Definition:
It refers to the radius of the arc formed when the cable is bent. The shortest distance from the cable body to the curve is measured based on the assumed center of the circle.
2) Measurement method:
Visually observe the shape of the cable curve and use a ruler to measure the distance from the false center to the cable body.
Standards and Specifications
1) General standards:
The bending radius of the automotive wiring harness is generally 5 times the outer diameter of the cable (such as an outer diameter of 10mm, the radius is ≥50mm).
2) High-voltage wiring harness requirements:
Additional protection is required for the relative movement between the wiring harness and the vehicle body to reduce wear.
The Impact of Too Small Bending Radius
1) Physical damage
Causes the cable insulation layer, sheath or internal conductor to rupture, affecting electrical performance and service life.
2) Hidden faults
Damage may not be discovered in time through conventional tests (such as insulation testing, resistance measurement), increasing later maintenance costs.
3) Construction restrictions
A too small radius may affect the installation of fixings such as cable tubes, resulting in difficulties in laying2.
Notes
1) The design should take into account the layout of the harness and the flexibility of the cable to avoid frequent sharp bending.
2) Special scenarios (such as high/low temperature environments) require the selection of heat-resistant materials (such as PUR/TPE sheaths) to adapt to temperature changes.
3) The following is the ratio of the bending radius to the diameter of different harness materials, for reference only:
Hard wire tube: The bending radius is not less than 3 times the diameter of the tube
Soft wire tube: The bending radius is not less than 2 times the diameter of the tube.
Round harness: The bending radius is not less than 4 times the diameter of the harness.
Flat harness: The bending radius is not less than 6 times the thickness of the harness.
