Design Solutions for Vehicle Wiring Applications

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Sophie Briggs
5 years ago
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1 Design Solutions for Vehicle Wiring pplications

about us - OEM design culture Harnessflex is a leading designer and manufacturer of flexible conduit systems and connector interfaces, protecting critical electrical and

abrasion, liquid ingress and corrosive salts.

malfunction and failure, compromising the operation of a vehicle.

ombining a full range of slit and un-slit conduit, fittings and connectors, we also offer the largest range of hinged system components and connector interfaces within the

2 about us - OEM design culture Harnessflex is a leading designer and manufacturer of flexible conduit systems and connector interfaces, protecting critical electrical and electronic wiring assemblies in the automotive industry, principally focussed on chassis and engine manufacturers within bus, truck, agricultural vehicle and heavy machinery markets. With a network of specialist distributors and the experience of our own sales engineers, Harnessflex can respond speedily to the most demanding of customer requirements anywhere in the world. With literally thousands of combinations the Harnessflex system offers the complete solution for routing and protection of electrical wiring against damage by mechanical abrasion, liquid ingress and corrosive salts. The use of connector interfaces ensures that there are no vulnerable connectors exposed to the elements, impact of foreign bodies and jet washing, which could so easily cause malfunction and failure, compromising the operation of a vehicle. Our success has come from our systematic commitment to providing an extensive range of high-grade quality components. ombining a full range of slit and un-slit conduit, fittings and connectors, we also offer the largest range of hinged system components and connector interfaces within the industry. ased in the UK we manufacture to internationally recognised quality and environmental standards ensuring that our products are safe and reliable. global market Manufacturers of vehicle harnesses operate on a truly global scale. Our products can be found on vehicles and engines throughout the world in frica, merica, ustralia, Europe, the Middle East and the Far East where we have been working with our customers for many years. markets The Harnessflex system is suitable for use on vehicles in a wide variety of markets and geographical locations. We can provide harness solutions for: gricultural Vehicles. onstruction Vehicles Engine Manufacturers Harness Manufacturers Truck & us Manufacturers Tanker & Trailer Manufacturers Specialist Vehicle omponents Military Vehicles 2 tel: +44 (0)

3 ontents ontents onduit 4-14 N 6-7 TP 8-9 HN 10 P 11 PP 12 DSPP 13 PK 14 Hinged fittings Joiners 16 Elbows 17 Tee Pieces Y Pieces Shrouds 22 X Pieces 23 Manifolds 24 Split Manifolds 25 ircular Manifolds 26 Sealed Fittings Straights Elbows o degree flanges 52 Tee's 53 X Pieces 54 Manifolds 55 ircular UNEF 56 Solenoid onnectors 57 Reducers 58 Glands 59 ccessories lips Technical Interfaces mp Superseal 28 mp Junior 29 mpseal 30 mp P 31 Deutsch DT Deutsch DT04 34 Deutsch DR50 35 FI 36 osch compact 37 Delphi Series Kostal 40 Milflex S 41 DIN ircular onnectors 43 Other Interfaces 44 ccessories

4 Selection table for onduit onduits N (Polyamide 6) TP (Polyamide 6) HN (Polyamide 11) P (FR o-polyester) PP (Polypropylene) DSPP (FR Polypropylene) PK (Polyetheretherketone) atalogue Page no Static temp. ( o ) Min Max UV Resistance Flexibility Fatigue Life Halogen Free Self Extinguishing External Wear Resistance Slit version available Slit only hemical Resistance IRM 903 (STM Oil No.2) S S S S S S S Diesel Oil S S S S S S S Ethylene Glycol (nti-freeze) S S S S S S S Lubricating Oil S S S S S S S Methyl lcohol L L S S S S S Parafin Oil S S S S S S S Petrol S S S S S S S Sodium hloride S S S S S S S Sodium Hydroxide (10%) S S S S S S S Transformer Oil S S S S S S S Urea S S S NT NT NT S Vegetable Oil S S S S S S S Sea (Water) S S S S S S S Key: S = Suitable, L = Limited Suitability, U = Unsustainable, NT = Not Tested. ll chemicals tested for resistance at 33 o. Maximum Performance = 4 tel: +44 (0)

Design Interaction Ingress Protection (I.P.) ratings Harnessflex hinged systems are rated at IP40. Harnessflex Sealed systems are rated at IP66, 67, 68 (2 R for 30mins) & 69k.

Other colours and materials can be made available to achieve specific customer requirements.

design data Harnessflex parts are developed in house using the following D systems: PT Pro-Engineer Wildfire 2 & 3.

5 Design Interaction Ingress Protection (I.P.) ratings Harnessflex hinged systems are rated at IP40. Harnessflex Sealed systems are rated at IP66, 67, 68 (2 R for 30mins) & 69k. product specifications ll Harnessflex fittings are manufactured from Polyamide 6,6 (P 6,6) and are black in colour. Other colours and materials can be made available to achieve specific customer requirements. Product datasheets and dimension charts are available for the full Harnessflex range - please submit your request via our website or call the Harnessflex technical support desk. design data Harnessflex parts are developed in house using the following D systems: PT Pro-Engineer Wildfire 2 & 3. utodesk Inventor V10, V11 & 2008 utodesk utod 2006, 07 & 08 Drawing files are available in the following D formats (as well as the versitile PDF format): DWG, DXF, DWF, IGES, STEP, STL, PRT, SM, IPT, IM. pre-production samples From D data we are able to produce accurate representations of final manufactured products, using a 3D printing process. Prototype fittings are typically produced in Duraform P, a material that gives similar performance in tests to P 6,6. Prototype extrusions can be manufactured in a variety of materials (please contact us for details). This process allows a product design to be validated before the part is tooled for manufacture. technical support Worldwide sales support via our experienced engineers. Please contact us to discuss any of our products, or the possibility of developing a solution specific to your needs. 5

6 N Standard weight Polyamide 6 General purpose conduit Description Flexible standard weight nylon (P6) conduit is a general-purpose conduit suitable for automotive harness applications. It can withstand extremes of temperatures and resists automotive oils and solvents. It is extremely tough and has a high impact strength and fatigue life. N conduit configurations and dimensions Solid N conduits provide protection against mechanical shock and ingress of water whilst maintaining their form through tight bend radii. pplications N standard weight is extensively used in harnesses on HGV, off road vehicles and marine applications where a superior protection against impact and mechanical shock is preferred. The conduit is used for both chassis and engine applications and can be used in a wide range of temperatures. Polyamide 6 is highly resistant to all hydrocarbon based oils and fluids and many types of solvents. N is designed for connection to all Harnessflex sealed and hinged system fittings. N conduits are available in a range of popular sizes. The standard colour is black with other colours also being available on request. onfiguration/nominal dimensions/part numbers Part onduit Nominal Min Min static Reel (N) (NW) (m) N N N N N N N N N N N tel: +44 (0)

7 N Slit Standard weight Polyamide 6 General purpose conduit N Slit conduit configurations and dimensions onfiguration/nominal dimensions/part numbers Part onduit Nominal Min Min static Reel (N) (NW) (m) N06-S N08-S N10-S N12-S N16-S N20-S N25-S N28-S N32-S N40-S N50-S Hints & Tips Kwikcut is the ideal cutting tool for all nonmetallic conduits upto 32mm. cutting instructions Place the conduit between the cutting blade and lower support, squeeze the handles and rotate the conduit for a clean, easy cut. Spare blades are available part no.s Kwikcut Kwikcut-lade 7

8 TP, Lightweight Polyamide 6 Flexible conduit Description Flexible lightweight nylon (P6) conduit is a general-purpose conduit suitable for automotive harness applications. It can withstand extremes of temperatures and resists automotive oils and solvents. It is extremely tough and has a high impact strength and fatigue life. TP conduits provide protection against mechanical shock and ingress of water whilst maintaining their form through tight bend radii. TP conduit configurations and dimensions pplications Lightweight convoluted tube used for interior harnesses offering limited mechanical protection to provide abrasion resistance and enhance the aesthetics of the harness. Extremely light and fexible. Resistant to oils and solvents. onfiguration/nominal dimensions/part numbers Part onduit Nominal Min Min static Reel (N) (NW) (m) TP TP TP TP TP TP TP TP TP TP tel: +44 (0)

9 TP Slit, Lightweight Polyamide 6 Flexible conduit TP conduit configurations and dimensions onfiguration/nominal dimensions/part numbers Part onduit Nominal Min Min static Reel (N) (NW) (m) TP08-S TP10-S TP12-S TP16-S TP20-S TP25-S TP28-S TP32-S TP40-S TP50-S Hints & Tips Kwikcut is the ideal cutting tool for all nonmetallic conduits upto 32mm. cutting instructions Place the conduit between the cutting blade and lower support, squeeze the handles and rotate the conduit for a clean, easy cut. Spare blades are available part no.s Kwikcut Kwikcut-lade 9

10 HN, standard weight Polyamide 11, Low temperature Extra flexible conduit Description HN standard weight conduit is made from polyamide 11 and is specially formulated to meet the environmental and mechanical requirements for the exterior of working vehicles. HN conduit configurations and dimensions HN conduit also provides protection against mechanical shock and ingress of water whilst maintaining its form through tight bend radii. It has been specifically designed to cope with extremes of temperature combined with repeated movement and vibration. pplications HN conduit is particularly used in applications requiring repeated flexing coupled with low temperature impact toughness. Robotics, rapid or continuous motion applications demanding high fatique life and extra flexibility are covered by HN which is also used in low temperature environments. HN Standard weight conduit is designed for connection to all Harnessflex hinged and sealed fittings. onfiguration/nominal dimensions/part numbers Part onduit Nominal Min Min static Reel (N) (NW) (m) HN HN HN HN HN HN HN HN HN tel: +44 (0)

11 P, medium weight (FR o-polyester) flame retarded conduit Description P standard weight conduit is made from flame retarded co-polyester, which is a halogen free, low smoke and very low toxicity material. It has excellent high and low temperature properties. P conduit configurations and dimensions P conduits provide protection against mechanical shock and ingress of water whilst maintaining their form through tight bend radii. This material demonstrates excellent chemical resistance to greases, hydrocarbons, fuels and oils. pplications P is particularly used in applications requiring low fire hazard performance, it is lightweight and retains its flexibility at extremes of temperature. P is designed for use in the interior and exterior of vehicles and marine passenger cabins. P is designed for connection to all Harnessflex Hinged and Sealed fittings. onfiguration/nominal dimensions/part numbers Part onduit Nominal Min Min static Reel (N) (NW) (m) P P P P P P P P P Hints & Tips Kwikcut is the ideal cutting tool for all nonmetallic conduits upto 32mm. cutting instructions Place the conduit between the cutting blade and lower support, squeeze the handles and rotate the conduit for a clean, easy cut. Spare blades are available part no.s Kwikcut Kwikcut-lade 11

12 Modified PP, medium weight Polypropylene conduit Description PP is a flexible conduit made from Polypropylene. PP conduits provide very good acid resistance, they have very good flexibility and a very high fatigue life. pplications PP is particularly used in lighter applications where compression strength and LFH is not so important. The main property of this conduit, being acid resistance. Halogen free not self-extinguishing PP conduits are available in a range of popular sizes. The conduit comes in black only. PP is designed for connection to all Harnessflex Sealed and Hinged system fittings. Modified PP conduit configurations and dimensions onfiguration/nominal dimensions/part numbers Part onduit Nominal Min Min static Reel (N) (NW) (m) PP PP PP PP PP PP PP tel: +44 (0)

13 Deep Section Modified Slit PP Polypropylene, Medium weight conduit Description Deep section PP conduit configurations and dimensions DSPP conduit is made from a halogen free, flame retarded material and although meeting the requirements of IE61386, would not be considered LFH. DSPP slit conduits provide protection against mechanical shock whilst maintaining its form through tight bend radii. pplications DSPP is particularly used in light weight applications where LFH and compression properties are not as important. DSPP is designed for connection to all Harnessflex Hinged and Sealed fitings. onfiguration/nominal dimensions/part numbers Part onduit Nominal Min Min static Reel (N) (NW) (m) DSPP DSPP DSPP DSPP DSPP DSPP DSPP DSPP Hints & Tips Kwikcut is the ideal cutting tool for all nonmetallic conduits upto 32mm. cutting instructions Place the conduit between the cutting blade and lower support, squeeze the handles and rotate the conduit for a clean, easy cut. Spare blades are available part no.s Kwikcut Kwikcut-lade 13

14 PK, standard weight Polyketone Super Low Fire Hazardonduit Description Super Low Fire Hazard PK is a standard weight conduit, which offers superior mechanical strength as well as high radiation and chemical protection often in extreme temperatures. It is a unique product manufactured from a specialist polymer, for use in the most demanding applications PK conduit configurations and dimensions Peek is a truly high performance conduit. pplications This conduit with its high specification performance is used in some of the most demanding applications for flexible conduit. It is often found in erospace, Off-shore, Military, Heat treatment, Nuclear, Petrochemical and Marine application onfiguration/nominal dimensions/part numbers Part onduit Nominal Min Min static Reel (N) (NW) (m) PK PK PK PK PK PK tel: +44 (0)

Product Catalogue. Providing superior protection for automotive wiring harnesses

Product Catalogue. Providing superior protection for automotive wiring harnesses Product atalogue Providing superior protection for automotive wiring harnesses Providing superior protection for automotive wiring harnesses Introduction onduit Hinged fittings Interfaces Sealed fittings