Let’s check out the reasons step by step. <\/p>\n\n\n\n
Wading Depth of a Vehicle<\/strong><\/h3>\n\n\n\nYou might have observed that on each vehicle, there is a line indicating the deepest water level it can cross at 10km\/h. <\/p>\n\n\n\n
This line is called the wading line; its height from the ground level is the “wading depth” <\/strong>of the vehicle. <\/p>\n\n\n\nWhile designing an automobile, the engineers consider these factors to fix the electric components above this line so they do not expose them to water. <\/p>\n\n\n\n
If they have to set any component below this line, they apply an extra waterproof material over them. <\/p>\n\n\n\n
On these bases, you can divide all the vehicle wiring harnesses into the following parts. <\/p>\n\n\n\n
\n- Ceiling<\/li>\n\n\n\n
- Front Bumper<\/li>\n\n\n\n
- Chassis and all wheels<\/li>\n\n\n\n
- Rear Door<\/li>\n\n\n\n
- Rear Bumper (above the line)<\/li>\n\n\n\n
- Back insurance (below the line)<\/li>\n\n\n\n
- Cab and Passenger side (compartment)<\/li>\n\n\n\n
- The 4-door line above the wading line<\/li>\n\n\n\n
- The 4-door line below the wading line<\/li>\n\n\n\n
- Frame beam part of the engine compartment<\/li>\n\n\n\n
- The peripheral portion of the engine\/ frame beam of the engine<\/li>\n<\/ul>\n\n\n\n
Dry and Wet Area, and Wire harness fixation<\/strong><\/h3>\n\n\n\n![\"Large](\"https:\/\/wiretroop.com\/wp-content\/uploads\/2023\/04\/1-13.jpg\")
<\/figure>\n\n\n\nCaption: Large wide cable in car module<\/p>\n\n\n\n
As we have classified the car portions, you can see which parts are more exposed to water. <\/p>\n\n\n\n
These parts, like the chassis, wheels, front bumper, rear bumper, and the 4-door line, require waterproof treatment before setting it up in the car.<\/p>\n\n\n\n
Additionally, some other components like lower areas of rear doors, front and back guard areas, ceiling, and engine rooms also get exposed to rain, etc. simultaneously. <\/p>\n\n\n\n
Now these parts have a significant amount of wiring in them. <\/p>\n\n\n\n
It includes a front cabin harness, powertrain wiring, rear bumper, 4-door, and battery’s +ive and -ive wire harnessing. <\/p>\n\n\n\n
All these harnesses require water protection, so they use electrical connectors<\/a> to seal the parts and block the water flow. <\/p>\n\n\n\nMoreover, engineers use heat-shrink tubing to cover the check-in points. <\/p>\n\n\n\n
Except for the abovementioned areas, all the other vehicle parts are usually classified as the dry zone. <\/p>\n\n\n\n
The ceiling, right\/left floor, and instrument wire harness are here. These areas need little to no water protection since they are not exposed to water. <\/p>\n\n\n\n
But, if the engineers see that they connect to the outdoors in any manner, it is obligatory to use a sealed cable tie buckle with them.\u00a0\u00a0<\/p>\n\n\n\n
How to design a waterproof wire harness? <\/strong><\/h2>\n\n\n\nYou can use the following methods to design a waterproof wiring harness for the vehicle. <\/p>\n\n\n\n![\"Rodent](\"https:\/\/wiretroop.com\/wp-content\/uploads\/2023\/04\/2-13.jpg\")
<\/figure>\n\n\n\nCaption: Rodent Damage to the car wiring<\/p>\n\n\n\n
Wire Harness Arrangement protection <\/strong><\/h3>\n\n\n\nPlaying with the harness position and arrangement allows you to achieve water resistance without using fancier components. <\/p>\n\n\n\n
If it lays flat, water tends to seep into the wiring due to gravity. <\/p>\n\n\n\n
To cater to the issue, you can use a three-dimensional design from the beginning of the vehicle manufacturer and fix the wires according to it. <\/p>\n\n\n\n
Moreover, the grounding point of the wires can be a weak link. <\/p>\n\n\n\n
So fixing the wires above the ground level can also lessen the water penetration inside them. <\/p>\n\n\n\n
However, you must still use effective insulation<\/a> on each wire to minimize risks. <\/p>\n\n\n\nAnother vulnerable area of the vehicle in terms of moisture is the one close to the water drainage point, which includes door and rear guard wire harnessing. <\/p>\n\n\n\n
The arrangement of the wires can also protect you from the water seepage in this area. <\/p>\n\n\n\n
You only need to fix the harness at an angle that can flow the incoming water outside the car. <\/p>\n\n\n\n
That way, there will be no intact droplets, and you will receive maximum protection. <\/p>\n\n\n\n
Sealing<\/strong><\/h3>\n\n\n\nUsing seals for protecting critical points of the vehicle is an old yet effective method. <\/p>\n\n\n\n
You may have observed that the temperature rises as they move and falls off as the vehicle stops working. <\/p>\n\n\n\n
The siphon phenomenon indicates the same behavior, pointing out that the occurrence of pressure differences causes water to seep in. <\/p>\n\n\n\n
Water can attack the gaps in copper wires while damaging the electric system. <\/p>\n\n\n\n
Hence to fill in these gaps, you can use glued heat-shrink tubing.<\/p>\n\n\n\n
Furthermore, if the harness involves a metal sheet, you can use rubber covers for insulation.<\/p>\n\n\n\n
Here you can find two types of metal shield installation, one with a fixed wire harness and the other for moveable parts. <\/p>\n\n\n\n
To fix the wire harness, you have to look for the position of the harness before and after the installation. <\/p>\n\n\n\n
Also, you will keep the indoor harness slightly higher than the outdoor one. <\/p>\n\n\n\n
If the sheet connects moveable parts, your best bet is to use rubber insulation so that there is little to no friction in the movement of the components. <\/p>\n\n\n\n
Moreover, consider the position of the holes of these parts and make the outer hole lower than the metal sheet’s hole. <\/p>\n\n\n\n
Selection of Waterproof Connectors<\/strong><\/h3>\n\n\n\nA vehicle’s connections can be used for linking two wires together and providing protection to the joining points. <\/p>\n\n\n\n
Hence, making connectors with proper waterproof sealing plugs and clips in place would be best. <\/p>\n\n\n\n
Another point to consider before choosing a connector is that these joining points dissipate heat while working. <\/p>\n\n\n\n
As per the rule, the amount of heat a connector can endure is the sum of temperature rise and the ambient temperature of the contact.<\/p>\n\n\n\n
Hence, buy connectors compatible with your vehicle’s heat dissipation. <\/p>\n\n\n\n
You will also face connector melting, which will destroy the electric module. <\/p>\n\n\n\n![\"Waterproof](\"https:\/\/wiretroop.com\/wp-content\/uploads\/2023\/04\/3-9.jpg\")
<\/figure>\n\n\n\nCaption: Waterproof connectors in the car wiring system<\/p>\n\n\n\n
Harness Winding Method<\/strong><\/h3>\n\n\n\nFor extra protection, you can use four harness winding methods. It includes <\/p>\n\n\n\n
\n- The whole vehicle winding<\/li>\n\n\n\n
- Thick winding <\/li>\n\n\n\n
- Double winding <\/li>\n\n\n\n
- \u2154 winding package methods. <\/li>\n<\/ul>\n\n\n\n
You can adopt two methods: semi-encapsulation and in-vehicle winding, rough winding. <\/p>\n\n\n\n
In semi-encapsulation, you will bind the wires into a bundle using insulation tape at intervals half the tape’s size. <\/p>\n\n\n\n
On the other hand, in the rough wind, you will bind the wire bundle with tape spacing 1.5 times the tape width. <\/p>\n\n\n\n
Ensure that the tape’s sticking side is not exposed to the air. <\/p>\n\n\n\n
You must apply special waterproofing treatments for critical wire harnesses like powertrain and adhesive ones, as they are usually exposed to the environment. <\/p>\n\n\n\n
Moreover, the door wire harness also requires extra protection as water splashes onto them while car washing and rain. <\/p>\n\n\n\n
The semi-encapsulation works best to stop water penetration and prevent short circuits.\u00a0<\/a><\/p>\n\n\n\nAdditionally, you can use the cross-wounding on any exposed wires. <\/p>\n\n\n\n
First, you can semi-encapsulate the wire harness and apply the waterproof rings and through-hole rubber sleeves. <\/p>\n\n\n\n
Conclusion<\/strong><\/h2>\n\n\n\nWater protection is a must while dealing with electrical components since continuous exposure to moisture encourages oxidation, and the wires’ performance also deteriorates with time. <\/p>\n\n\n\n
In addition, non-functioning wires may result in complete failure most of the time. <\/p>\n\n\n\n
While designing an automobile, the engineers consider these factors to fix the electric components above this line so they do not expose them to water. <\/p>\n\n\n\n
If they have to set any component below this line, they apply an extra waterproof material over them. <\/p>\n\n\n\n
On these bases, you can divide all the vehicle wiring harnesses into the following parts. <\/p>\n\n\n\n
- \n
- Ceiling<\/li>\n\n\n\n
- Front Bumper<\/li>\n\n\n\n
- Chassis and all wheels<\/li>\n\n\n\n
- Rear Door<\/li>\n\n\n\n
- Rear Bumper (above the line)<\/li>\n\n\n\n
- Back insurance (below the line)<\/li>\n\n\n\n
- Cab and Passenger side (compartment)<\/li>\n\n\n\n
- The 4-door line above the wading line<\/li>\n\n\n\n
- The 4-door line below the wading line<\/li>\n\n\n\n
- Frame beam part of the engine compartment<\/li>\n\n\n\n
- The peripheral portion of the engine\/ frame beam of the engine<\/li>\n<\/ul>\n\n\n\n
Dry and Wet Area, and Wire harness fixation<\/strong><\/h3>\n\n\n\n
<\/figure>\n\n\n\nCaption: Large wide cable in car module<\/p>\n\n\n\n
As we have classified the car portions, you can see which parts are more exposed to water. <\/p>\n\n\n\n
These parts, like the chassis, wheels, front bumper, rear bumper, and the 4-door line, require waterproof treatment before setting it up in the car.<\/p>\n\n\n\n
Additionally, some other components like lower areas of rear doors, front and back guard areas, ceiling, and engine rooms also get exposed to rain, etc. simultaneously. <\/p>\n\n\n\n
Now these parts have a significant amount of wiring in them. <\/p>\n\n\n\n
It includes a front cabin harness, powertrain wiring, rear bumper, 4-door, and battery’s +ive and -ive wire harnessing. <\/p>\n\n\n\n
All these harnesses require water protection, so they use electrical connectors<\/a> to seal the parts and block the water flow. <\/p>\n\n\n\n
Moreover, engineers use heat-shrink tubing to cover the check-in points. <\/p>\n\n\n\n
Except for the abovementioned areas, all the other vehicle parts are usually classified as the dry zone. <\/p>\n\n\n\n
The ceiling, right\/left floor, and instrument wire harness are here. These areas need little to no water protection since they are not exposed to water. <\/p>\n\n\n\n
But, if the engineers see that they connect to the outdoors in any manner, it is obligatory to use a sealed cable tie buckle with them.\u00a0\u00a0<\/p>\n\n\n\n
How to design a waterproof wire harness? <\/strong><\/h2>\n\n\n\n
You can use the following methods to design a waterproof wiring harness for the vehicle. <\/p>\n\n\n\n
<\/figure>\n\n\n\nCaption: Rodent Damage to the car wiring<\/p>\n\n\n\n
Wire Harness Arrangement protection <\/strong><\/h3>\n\n\n\n
Playing with the harness position and arrangement allows you to achieve water resistance without using fancier components. <\/p>\n\n\n\n
If it lays flat, water tends to seep into the wiring due to gravity. <\/p>\n\n\n\n
To cater to the issue, you can use a three-dimensional design from the beginning of the vehicle manufacturer and fix the wires according to it. <\/p>\n\n\n\n
Moreover, the grounding point of the wires can be a weak link. <\/p>\n\n\n\n
So fixing the wires above the ground level can also lessen the water penetration inside them. <\/p>\n\n\n\n
However, you must still use effective insulation<\/a> on each wire to minimize risks. <\/p>\n\n\n\n
Another vulnerable area of the vehicle in terms of moisture is the one close to the water drainage point, which includes door and rear guard wire harnessing. <\/p>\n\n\n\n
The arrangement of the wires can also protect you from the water seepage in this area. <\/p>\n\n\n\n
You only need to fix the harness at an angle that can flow the incoming water outside the car. <\/p>\n\n\n\n
That way, there will be no intact droplets, and you will receive maximum protection. <\/p>\n\n\n\n
Sealing<\/strong><\/h3>\n\n\n\n
Using seals for protecting critical points of the vehicle is an old yet effective method. <\/p>\n\n\n\n
You may have observed that the temperature rises as they move and falls off as the vehicle stops working. <\/p>\n\n\n\n
The siphon phenomenon indicates the same behavior, pointing out that the occurrence of pressure differences causes water to seep in. <\/p>\n\n\n\n
Water can attack the gaps in copper wires while damaging the electric system. <\/p>\n\n\n\n
Hence to fill in these gaps, you can use glued heat-shrink tubing.<\/p>\n\n\n\n
Furthermore, if the harness involves a metal sheet, you can use rubber covers for insulation.<\/p>\n\n\n\n
Here you can find two types of metal shield installation, one with a fixed wire harness and the other for moveable parts. <\/p>\n\n\n\n
To fix the wire harness, you have to look for the position of the harness before and after the installation. <\/p>\n\n\n\n
Also, you will keep the indoor harness slightly higher than the outdoor one. <\/p>\n\n\n\n
If the sheet connects moveable parts, your best bet is to use rubber insulation so that there is little to no friction in the movement of the components. <\/p>\n\n\n\n
Moreover, consider the position of the holes of these parts and make the outer hole lower than the metal sheet’s hole. <\/p>\n\n\n\n
Selection of Waterproof Connectors<\/strong><\/h3>\n\n\n\n
A vehicle’s connections can be used for linking two wires together and providing protection to the joining points. <\/p>\n\n\n\n
Hence, making connectors with proper waterproof sealing plugs and clips in place would be best. <\/p>\n\n\n\n
Another point to consider before choosing a connector is that these joining points dissipate heat while working. <\/p>\n\n\n\n
As per the rule, the amount of heat a connector can endure is the sum of temperature rise and the ambient temperature of the contact.<\/p>\n\n\n\n
Hence, buy connectors compatible with your vehicle’s heat dissipation. <\/p>\n\n\n\n
You will also face connector melting, which will destroy the electric module. <\/p>\n\n\n\n
<\/figure>\n\n\n\nCaption: Waterproof connectors in the car wiring system<\/p>\n\n\n\n
Harness Winding Method<\/strong><\/h3>\n\n\n\n
For extra protection, you can use four harness winding methods. It includes <\/p>\n\n\n\n
- \n
- The whole vehicle winding<\/li>\n\n\n\n
- Thick winding <\/li>\n\n\n\n
- Double winding <\/li>\n\n\n\n
- \u2154 winding package methods. <\/li>\n<\/ul>\n\n\n\n
You can adopt two methods: semi-encapsulation and in-vehicle winding, rough winding. <\/p>\n\n\n\n
In semi-encapsulation, you will bind the wires into a bundle using insulation tape at intervals half the tape’s size. <\/p>\n\n\n\n
On the other hand, in the rough wind, you will bind the wire bundle with tape spacing 1.5 times the tape width. <\/p>\n\n\n\n
Ensure that the tape’s sticking side is not exposed to the air. <\/p>\n\n\n\n
You must apply special waterproofing treatments for critical wire harnesses like powertrain and adhesive ones, as they are usually exposed to the environment. <\/p>\n\n\n\n
Moreover, the door wire harness also requires extra protection as water splashes onto them while car washing and rain. <\/p>\n\n\n\n
The semi-encapsulation works best to stop water penetration and prevent short circuits.\u00a0<\/a><\/p>\n\n\n\n
Additionally, you can use the cross-wounding on any exposed wires. <\/p>\n\n\n\n
First, you can semi-encapsulate the wire harness and apply the waterproof rings and through-hole rubber sleeves. <\/p>\n\n\n\n
Conclusion<\/strong><\/h2>\n\n\n\n
Water protection is a must while dealing with electrical components since continuous exposure to moisture encourages oxidation, and the wires’ performance also deteriorates with time. <\/p>\n\n\n\n
In addition, non-functioning wires may result in complete failure most of the time. <\/p>\n\n\n\n