In the manufacturing process of modern electrical and electronic equipment, wire harnesses play a crucial role. To ensure the safety and reliability of these products, wire harness manufacturers must adhere to multiple international standards, including the Delta 30°C (Δ 30°C) standard. This standard is a critical benchmark for evaluating the performance and reliability of wire harnesses.
The Delta 30°C (Δ 30°C) standard specifies that the temperature rise of a wire harness and its related components (such as connectors) under rated current conditions should not exceed 30°C. This means that the maximum working temperature of the product should be within 30°C of the ambient temperature. For example, if the ambient temperature is 25°C, the surface temperature of the wire harness and its connectors should not exceed 55°C.
The purpose of this standard is to prevent equipment overheating, ensure stable operation, and extend the lifespan of wire harnesses and connectors.
Meeting the Delta 30°C standard requires careful consideration throughout the manufacturing process:
1. Material Selection
Material selection directly affects the temperature rise performance.
1.1 Conductor materials: Choosing materials with high thermal conductivity and low electrical resistance is crucial. Copper or tin-plated copper are preferred materials for wire harnesses upon the high conductivity and low heat generation.
1.2 Insulation materials: High-temperature-resistant materials such as PVC, polyethylene, or silicone should be selected, which can withstand working temperatures of up to 105°C or even 200°C.
2. Processing Precision
2.1 Wire specifications: The copper wire after stripping should have no damage or wire breakage, and the number of cut copper wires should meet the specification limits.
2.2 Crimping process: The crimping height and width of the terminal should meet the drawing specifications, and the crimped joint should have no tears or damage, strictly following the technical parameters provided by the terminal manufacturer to ensure crimping force and contact resistance meet the standards.
2.3 Insulation crimping: The insulation layer after crimping should remain intact and pass the bending test.
3. Heat Dissipation Design
3.1 Wire harness layout: Reasonably arrange the wire harness to enhance ventilation and reduce heat accumulation.
3.2 Protective sleeve material: Select materials with good thermal conductivity for the outer protective sleeve to help dissipate heat.
As a professional wire harness manufacturer, Avertronics has an independent laboratory that can perform professional temperature rise testing to verify whether products meet the Delta 30°C standard.
As a professional manufacturer of waterproof connectors, Avertronics designs and produces products that meet the Delta 30°C standard.
With the rapid development of electric vehicles, smart homes, and industrial automation, the demand for wire harnesses is increasing, and the requirements for temperature rise performance are becoming more stringent. Wire harness manufacturers are actively adopting the following strategies:
The Delta 30°C standard is a cornerstone of wire harness quality and safety. By focusing on material selection, precision processing, and rigorous testing, manufacturers can deliver reliable, high-performance products that meet the demands of today's increasingly complex electrical and electronic systems.
