The Roadmap to Your HDV Success: What Standard You Need to Know for Wire Systems in 2019

As with many industries, the heavy-duty vehicle industry faces challenges with evolving safety standards and certification requirements. Many of these requirements may come from governments or regulatory agencies or may be more informal yet voluntary standards adopted by the industry. Staying familiar with these ever-changing regulations can be a daunting task, especially when factoring in regional or country-specific nuances.   

Every component you are designing into a product likely also has a required certification or standard that your product needs to be in compliance with. For instance, whether you are designing to transport people or goods, a heavy-duty vehicle will have a complex electrical wiring system. The electrical connectors and wiring materials you design into that system are critical, with the need to withstand dirt, debris, high heat, extreme cold, friction, corrosion and rigidity. Exposure to one of these elements and even the slightest damage to a small electrical component can cause havoc on the entire system.

With more than 50 years of proven experience in wire harness and heavy duty cable management, we know that designing with the right materials can mean the difference between meeting your complex specifications and regulatory requirements – or not. It is why we work so hard to push for standardization – not only to improve upon our own excellence, but to give the entire industry a benchmark upon which they can deliver quality products resulting in higher customer satisfaction, while improving their own productivity and profitability.

That is why changes happening this year are significant for those designing heavy-duty vehicles: the new ANSI UL 62275 publication has harmonized with CSA C22.2 No. 62275 (Canada), NMX-J-623-ANCE (Mexico) and IEC 62275 (Europe), establishing a standard type classification and performance ratings for plastic cable ties, mounts, metallic cable ties, and integral cable tie mounts.

Major changes include:

  1. A requirement of parallel entry metallic cable ties to be tested with the locking mechanism positioned at 9:00, whereas testing may have been conducted previously at 12:00.
  2. Coated metallic cable ties are currently classified as Type 21 products but will be classified as Type 2 under ANSI UL 62275.
  3. The contribution to fire test will now be needed to classify coated metallic cable ties as Type 2.
  4. Products classified as outdoor use products will be required to run the environmental exposure test at a spectral irradiance of 0.51, with the previous irradiance value being 0.35.
  5. Testing under ANSI UL 62275 will include tensile strength, minimum operating temperature, minimum installation temperature, minimum and maximum bundle diameter, UV resistance, vibration for metallic cable ties-cycling, corrosion, contribution to fire-needle flame, and plenum.

So what does this mean exactly?

The UL 62275 standard will be critical for the heavy-duty vehicles industry going because it ensures an increase in quality and safety. It also cuts down on the number of products to be tested, reducing the time, money and paperwork needed to ensure certification or compliance. Without harmonization, an OEM may be required to use different wire harness products based on a heavy-duty vehicle’s ultimate destination, taking up time and putting more pressure on workers to complete tests for each regional standard.

Instead, OEMs may now have more time for R&D to further advance their designs to better serve the end-user. Not only will this provide customers with better products, but will encourage a whole new host of innovation within the heavy-duty vehicle sector.

To get more insight into UL 622275, read our white paper Prepare for the Future: What Global Standards Harmonization Will Mean for the Wire Harness Industry.


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Reduce Time Needed to Validate: How Quality Tooling for Wire Systems Help You Achieve HDV Production Volume Faster

OEM Design Engineers know better than anyone how long it can take to thoroughly validate a new component or product to drive business value. When quality lacks in a product and it fails testing, nothing is more frustrating than needing to find a replacement – one that is not only responsible to both the cost and innovation – but that is able to pass all the testing without holding up the larger development and production timelines.

The heavy-duty vehicle industry is especially prone to quality challenges. Building machinery for some of the most variable and complex environments often involves custom design, assembly and maintenance. Heavy-duty vehicles must be durable to withstand dirt, debris, high heat, extreme cold, friction, corrosion and rigidity. Exposure to these elements or even slight damage to small wire components can strain an entire system. It is for this reason that durable and dependable wire harness systems for heavy-duty vehicles, while often overlooked, can make a huge impact in not only ensuring on-time production, but a product’s success in the industry.

So, what type of wire harness solutions can you incorporate to ensure a smooth pathway to production?

  1. Heavy Duty Cable Ties promoting design flexibility through added tensile strength, heavy duty cable ties can withstand internal and external temperatures and exceed industry standards for use in high vibration areas. Additional improvements in reliability and productivity can also be found by increasing bundle diameter variations.
  2. Automatic Cable Tie Tool – automatic cable tie installation systems can maximize bundling productivity six times faster than manual cable tie methods. Our PAT 4.0 Automatic Cable Tie Installation System can attach 84 cable ties per minute, which is 25 percent faster than other automatic cable tie systems, helping to reduce user fatigue and improve tool maneuverability.
  3. Harness Board System components – incorporating grid tiles and repositionable accessories can greatly improve the productivity of wire harness assembly builds. Panduit’s Quick-Build™ Harness Board System components such as grid tiles, mounting pegs, mounting platforms and grid tile connectors can help reduce layout and board build material costs as much as 65 percent, while delivering more than 50 percent in storage space savings by reducing the number of required bulky plywood boards.

One OEM that successfully implemented wire system solutions to maintain its continued excellence in the road transportation market is Iveco, the world’s leader in industrial special vehicles like firefighting, off-road missions, the military, and civil defense. The company needed to update its wire assembly during a system redesign of its Eurocargo truck in order to comply with the Euro 6 standard, which designated the acceptable limits for exhaust emissions of newly registered road vehicles sold in Europe.

Iveco worked with Panduit to install a complete fastening solution including cable tie mounts, plastic and stainless steel cable ties, accessories, and installation tools. Specifically, Iveco anchored two cables alongside the engine muffler on approximately 13,000 trucks – equaling about four cable tie mounts per vehicle. The solution to anchor those cables can withstand high temperatures up to 392°F, is weather resistant and has passed select chemical resistance tests. Iveco then improved its assembly line efficiency by using the PAT 4.0 system for installation, giving workers the ability to be more agile and install the fastening solution more quickly. With more than 50 years of experience in wire harness, heavy duty cable management and control panel solutions, Panduit has supported heavy-duty vehicle OEMs worldwide through its global manufacturing, warehousing and diverse technical and sales support capabilities. To learn how you can design wire assembly and bundling to be more productive for your heavy duty vehicle application, read our new eBook.