Aerospace Wiring Harness Guide

Aerospace wiring harness is a core component used in aircraft (such as airplanes and spacecraft) to connect electrical and electronic equipment, undertaking key functions such as energy transmission, signal control, and system interconnection. It is known as the "neural network" of aircraft.

The structural and functional requirements are as follows:

Composition elements

• Composed of wires, terminals, connectors, sheaths, etc., an integrated circuit is formed by crimping and bundling.
• Typical structures include metal mesh rope sleeves, high-temperature isolation coatings, protective silicone, etc., to prevent faults such as short circuits and fractures.

Core functions

• Power transmission and distribution: Provide power transmission for systems such as engines, landing gear, and avionics.
• Signal control: transmitting key signals such as flight control, navigation, and communication.

Special materials and performance requirements

• High temperature resistant materials: such as polyimide (PI), polytetrafluoroethylene (PTFE), etc., suitable for extreme temperatures ranging from -55 ℃ to 200 ℃.
• Anti radiation materials: using composite film wrapped insulation, nickel plated copper core, etc. to ensure stability in vacuum and radiation environments.
• Flame retardant material: Complies with UL94 V-0 and other fire protection standards, commonly coated with Fluorinated Ethylene Propylene (FEP).

Environmental adaptability

• Must withstand harsh conditions such as vibration, impact, salt spray, and fuel corrosion.
• Verify long-term reliability through atomic oxygen and ultraviolet aging tests.

The importance and application of wire harness connection

• Connecting flight control, engine, communication and other systems directly affects flight safety and availability.
• The total length of a plane's wiring harness can reach over 60000 meters, involving over 50000 components.

Weight loss and optimization

• Using lightweight materials (such as aluminum wires) and integrated design to reduce the weight of the wiring harness and improve aircraft performance. ‌

Safety and protective performance of aviation wiring harness

• Fireproof and flame retardant: The wire harness material must comply with aerospace fire protection standards (such as UL94 V-0) and use flame-retardant coatings or fluorinated ethylene propylene (FEP) materials.
• Resistance to mechanical stress: It has high tensile strength (≥ 50N/mm ²) and flexibility, suitable for repeated bending and vibration impact.

Aerospace wiring harnesses ensure the stable operation of aircraft in extreme environments through reliable design, application of special materials, and strict manufacturing standards. They are an irreplaceable "vascular and neural" system in the aviation industry.