Key Points of Wiring Harness Bandaging and Taping

The purpose of Wiring Harness outer packaging is mainly to be wear-resistant, flame retardant, anti-corrosion, anti-interference, reduce abnormal noise and improve appearance consistency.Different regions have different environments (temperature, oil pollution, water vapor, vibration, space), and the wrapping materials and methods should also be selected differently.

1) Bandaging design (make a plan in advance)

It is recommended to first divide the area according to the location of the Wiring Harness, and then determine the materials and fixing methods:

Engine/front cabin area: high temperature, oil pollution, and water vapor. Priority should be given to protective materials with high flame retardant grade, wear resistance, heat resistance, and waterproof performance (such as threaded pipes, high temperature resistant tape, etc.), and anti-wear treatment at contact points.

Instrument/cab area: The environment is relatively mild, and more attention is paid to noise reduction and appearance. You can use flannel tape, PVC tape or casing, etc., and pay attention to keeping a gap with moving parts.

Chassis area: There are many contact points with the car body. It is recommended to use bellows/casings, etc. to enhance wear resistance and ensure reliable fixation of ties/buckles.

2) General principles for wrapping tape

Do not overstretch: the tape will shrink and warp when stretched, affecting its appearance and lifespan.

Uniform overlap: The overlap amount remains consistent (usually about 1/2), and the corners are properly densed to avoid exposed lines or glue accumulation.

Compact the ends: Press firmly at the end, and if necessary, wrap 2-3 more turns for reinforcement to prevent flanging.

3) Straight lines are closely intertwined (trunk section)

Starting from the fixed point or end, keep the angle of the tape consistent and wind at a constant speed; the transition where the outer diameter of the Wiring Harness changes should be smooth to avoid forming "steps".

4) Processing of branch parts (easiest to loosen)

The branches should be positioned and fixed first (a small section can be cross-attached to form a "cross fixation"), and then wrapped around each branch respectively.Make sure the roots of the bifurcation are properly bandaged to avoid exposure and distortion.

5) Sparse wrapping (when heat dissipation/flexibility is required)

Use sparse wrapping when better flexibility or heat dissipation is required: leave equal intervals between tapes and keep them even.If the spacing is too large, the threads will be easily exposed and worn, while if the spacing is too small, it will be equivalent to dense entanglement.

6) Appearance and quality inspection

Check points: whether there are warping, wrinkles, and flanging; whether the roots of branches are loose; whether there are twisted tapes; whether there are obvious bulges, exposed lines, or scratches; whether the fixed points are firm and do not interfere with moving parts.

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