Wire assembly for automotive pressure switch system
Product Description
This custom wire assemblies applied for automotive pressure switch system to FAN, RELAY parts. which processed with special copper ultrasonic welding for wire joint connection, which replaced common splice PNT terminal.
We have developed a tradition of high-tech engineering, prototyping, and quality Custom Cable manufacturing at very competitive pricing for wire assembling. Also with professional flow chart (wire cutting-stripping-copper twisting-crimping-crimping 100% inspection-soldering-molding-asssembling-braiding-testing-FQC100% -OQC) , which can help us support customers with stable quality.
Product Specifications
| Product Name | wire assembly for automotive pressure switch system | ||
| Application | automotive pressure switch system | ||
| Cable color | Per customer requirements | ||
| Cable Length | Per customer requirements | ||
| Outer Insulation Material | XLPE(Irradiated wire) | ||
| Cable Jacket | XLPE automtive wire GXL, TXL | ||
| Connectors type | originanl or local equivalent auto relay connector, auto waterproof fuse connector, auto molded plug as customer request | ||
| Pin out connection | As per customer’s request | ||
| Inner Copper | Tin-plated / Bare Copper | ||
| Cable protection | Covered with split corrugated tube 94V-0 & 3M taping | ||
| Joint connection | Ultrasonic welding replaced common splice terminal | ||
| Quality Certificate | ISO9001, IATF16949, ROHS, UL,SGS,REACH | ||
| Performance Test: | 100% terminal inspection & 100% electric testing & 100% FQC & AQL=0.65 | ||
Product Details
01 And the joint connected terminal all crimped following IPC620-C standard, to use ultrasonic welding method to repalce common splice terminal. The welded appearance as below, together with the required welding spec and Ultrasonic quality controlling
02 Poor quality:
a)Insulation is embedded in weld nugget
b)End of insulation is lesss than 1 wire diameter or more than 2 wire diameters from weld nugget.
c)Insulation gap is so large that it causes the conductor toviolate minimum electrical spacing.
d)Any loose wire strands, any discoloration of the conductors;
e)Nugget width to height ratio is less than 1 to 1 or exceeds 2 to 1.
ETOP controlled quality:
a) End of insulation is between 1 and 2 wire diameters from weld bugget;
b) Nugget width to heigt ratio is 1.5 to 1; or at least 1 to 1 but does not exceed 2 to 1;
c) Individual wire strands are distinguishable on compression surfaces（top & bottom) of nugget. And there are no loose strands.
03 The IP67 waterproofing fuse box with local equivalent one, which can be customized to be original AVL one. Fuse is 5A, also the connector designed with waterproofing silicone seal and cap.
04 The 5pin automitve relay connector with locking hook to fix during assembling. The Automotive relays are for use in 12 volt electrical systems.Relays are used when you need to switch higher currents than a switch can handle, or when you want to isolate an electrical circuit.
Product Video
Here is the vedio for ultrasonic welding fixture testing and process.
Product Applications
The pressure switch is an important component on many of our electric models. This customized auto wire assembly are applied for automotive air conditioner's pressure switch system, which cycles the vehicle's compressor on and off when the refrigerant pressure falls below an acceptable level. This protects the compressor from damage.
The ETOP custom automobile wiring harnesses are also used for audio, ECU, Hybird battery, engine, GPS, mirror, rear-view, ADAS, auto seat, Buzz and sensor, Lamp, dieseal valve cover gasket fit, fuel pump, diagnostic OBD system., etc.