harness sealing

8/12/2019 Harness Sealing

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Wire Harness SealingTechnology

CTIS # 29951Prepared By John Yurtin

Updated 1-20-2005

Connection Systems Training


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Having a good technical understanding of the products andthe technology behind them will help in choosing the rightproduct for the application

This training help you understand harness sealing, and theproducts and technologies available so you can make betterharness sealing decisions..

Excellence

Performance Goal: Do itright the first time everytime

Method: Innovation andcontinuous improvement


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Wire Harness Sealing Methods


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Harness - Sealing

Splash WaterSealingInjection MouldingLoose Piece Grommets

(Rubber EPDM)

Shrinking GrommetsBulkhead ConnectorsCoverings

(tubes, tapes, etc.)

Longitudinal / BundleSealingCold PasticineHot MeltPUR FoamingCapillary Action

PreventionSLS Process

Overview


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A. Cold Plasticine (Butylene rubber)

A1. - Manual Assembly (Terostat) A2. - With Auxiliary Devices

A2.1 Tyton

A2.2 Cold Melt 1 A2.3 Cold Melt 2

B. Hot Melt

B1. - OvermouldingB2. - Hot Melt + Shrinking Procedure(Rayblock LMX)

C. PUR Foaming

Methods For Bundle Sealing


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Pros:

- low price- no capital expenditure- simple method- usable for rework

Cons:- no reliable process- depends on operator- maybe sealing

A. Cold Plasticine (Butylene rubber) A1. - Manual Assembly (Terostat)

Longitudinal / Bundle Sealing


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Pros:- very low capital expenditure- in comparison to Method A1:

easier Handling Cons:

- Process Reliability

- costly Handling

A. Cold Plasticine (Butylene rubber) A2. - With Auxiliary Devices

A2.1 Tyton



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Pros:- very low capital expenditure- in comparison to Method A1:

easier Handling

Cons: Process Reliability

- costly Handling

A. Cold Plasticine (Butylene rubber)

A2. - With Auxiliary Devices A2.2 Cold Melt 1



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Pros:- Grommet assembeled on

harness- very low capital expenditure- in comparison to Method A1: easier Handling

Cons:- high material price depends

on design- Process Reliability- costly Handling

A. Cold Plasticine (Butylene rubber) A2. - With Auxiliary Devices A2.3 Cold Melt 2



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Pros:- Controlled Process- Easy Handling- High Capital Expenditure

(~40Thd DM per Machineplus Mould)

Cons:- only for small wire bundles

(less than 10 wires)

B. Hot Melt B1. - Overmoulding



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Pros: - see A2.2

Cons: - see A2.2

B. Hot Melt B2. - Hot Melt + Shrinking Procedure (Rayblock LMX)



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Pros:- Combination of 2 Operations

(Sealing + Grommet) in one Process Step- Noise Reduction

- Reduction of Manual Worktime- Reliability

Cons:- High Capital expenditure(~160thd DM per machine w/o Tools)

C. PUR Foaming



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Capillary Action Preventer


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13 way sealed Door connection

Advantages: New locking system with spring One hand mounting For left or right doors Easy assembly and dis-assembly

Doors-Off Connections


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Grommet/connector retainerProvides positive, one-handed installationof the grommet to the sheetmetal

Pre-staged MBSProtects blades during shipmentand vehicle assembly plantprocessing and handling

Positive Lever Lock Out Assures that the lever is in the proper

position at the time of assembly

Doors-off connections provide an easy means of connecting bodywiring to door wiring, especially if the doors are assembled off-line The system incorporates many patented Delphi design features Lever Lock mechanical assist means that high circuit count connections

can be mated with the fingers



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Connector Grommet/ConnectorRetainer

Design VersatilitySystems are designed to have the connector snap into thegrommet/connector retainer Allows the connector to be used elsewhere in the vehicle as part of an in-

line connection system Also allows the same connector to be used in a different door application

by simply changing the grommet/connector retainer geometry



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Connection system combines best in class features for mechanical assistsealing, and contact technology

Unique design provides tight contact packaging foroptimum use of space

Custom designed to enable improvements in vehicle assembly plant process



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Custom designed to enable vehicle assemblyplant process improvements

Connection system technology combines bestin class feature for mechanical assist, sealing,and contact technology

Mechanical assist feature is contained withinthe protective door grommet, optimizing thespace required



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Double Click on Photo to Activate Video Clip



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Compression Gasket

Male Terminals

Sealed Mating Connector

Metal Plate

Fuel Tank Pass-Through


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Grommets


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Multi-Piece Grommets


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Grommets


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Door Grommets


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Validated to Toyota TSC1156G and passed all the tests. Completed December 2003.

Build will start at the end of Jan. 2004 in Japan.

2001 TOYOTA RAV 4 FOD Grommet

Revisedopening

Largercore outfor tooling

Extended tubewith 15mm

Toyota 635N Dash Grommet


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44mm

30mm

A

A

BB Section A-A

Section B-B

Core outfortooling

63.5mm



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Additional Changes Harness branch location in the grommet is critical. The Branch must be centered during thedispensing of the polyurethane.

Polyurethane sealant and grommet (EPDM) are NOT chemically bonded. Gaps betweengrommet and sealant might be a leak pass.

The rib inside the tube helps cables beingcentered.

Thinner portion of the tube provides spacebetween cables and the grommet.

Cable



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Objectives To examine whether the revised grommet could accept One -shot application without overflow.

To examine the revised opening could accept

one-shot application.

To examine if upper level of sealantscould reach here.

Primary Sealing

SLS Grommet


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Click picture below to activate video

SLS Grommet Process

harness sealing

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