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Automobile engine requires three min electrical systems such as, the starting system, the generating

(charging) system, and the ignition system. The starting system cranks the engine for starting from its
idle condition. During vehicle running, the generating system, meets total vehicle electrical
requirements including charging of the battery. The ignition system supplies and electric spark in each
cylinder of the engine when the air-fuel mixture is compressed and ready for combustion. The battery
stores electrical energy needed to operate the vehicle electrical system when the engine is stationary,
or when the output from the generator is low.

The increased application of electrical and electronic systems in automobiles has necessitate
the used for complex electrical distribution system. A typical mid-priced, medium-size European car
of the 1990s uses more than 1.5km of wiring and more than 2000 terminals, connectors and relays,
and the weight of such an electrical distribution system exceeds 30kg.

The wiring harness is the major component of the electrical distribution system. This contains bundles
of cables, which connect all of the electrical parts. Sensors and actuators with electronic control units
in a vehicle. It serves two primary functions. These include (i) to act as a power distribution network,
and (ii) to act as an information distribution network.

The majority of vehicle breakdowns are caused by electrical failure, so vehicle reliability is
critically dependent upon good wiring harness design and implementation. Generally, the wiring
harness is divided into a main harness that runs the length of the vehicle connecting the battery to
the charging system, vehicle interior, lighting and accessory circuits, and various sub-harnesses, such
as door wiring, and roof. Wiring. Forb facilitating vehicle assembly and servicing, connector blocks
are used for connecting the sub-harnesses to the main harness.

Generally, cables are specified as per the strand diameter and number of strands. A cable with
specification as 7/0.3 is made from seven strands each 0.emm diameter. If an insulation thickness of
0.35mm is provided, a cable normally has a finished diameter of about 1.6 mm and is suitable for
carrying current up to about 4 A.

To reduce costs, manufacturing use the thinnest possible cable for a particular application in
a vehicle, without causing too much voltage drop. As a rule thumb, a maximum voltage drop of 5%
(i.e. 0.6V in a 12 V system) is allowed for general lighting and control circuits.

Normally, a current rating of about 8.5 A per square millimeters of cable cross-section is assumed. A
reduced rating of about 6 A per square millimeter is considered for continuously loaded cables.

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