KIA ES91101-00 Wiring Harness Standard Applied to Certain Components

The standard “KIA ES91101-00 Wiring harness standard applied to specific components” developed by Hyundai-Kia Motors Company, the oldest motor vehicle manufacturing company in Korea, describes a procedure for determining the wiring harness standard (wiring process) applied to the components specified in this standard. The quality of materials must comply with all the requirements of this standard.

The scope of application of this standard is determined as follows:

• This standard applies to vehicle wiring, however, larger fastening areas secured with hardware (bolt/nut) comply with the ES91101-02 standard.
• If the instructions in the drawing differ from these standards, the instructions in the drawing take precedence.
• All randomly selected samples from the prototype process and the production process (including the pilot process) must meet this specification to perform the process specified in this document.
• The relevant supplier must establish a reliability verification system on its own to qualify the design of the part with a sufficient number of samples.

For the purposes of this standard, the following terms and definitions apply:

• Wiring harness: It refers to the wiring harnesses consisting of wiring, connectors, protectors, holding devices and others, and transmits power and current from a vehicle.
• Splice connection: It connects two or more cables together, and its metal structure holds the conductors of several unsheathed cables together.
• Heat shrinkable tube: When heat is given to the applied tube type material, it fixes the materials to the cable surface with its feature of shrinking the outer diameter, this is applied to prevent short circuits in case the exposed part of the cable type material holds the conductor of the other part.
• Heat shrink adhesive tube: It is a type of shrink tube and has the function of ensuring that external moisture does not penetrate into the inside of the tube due to the adhesive in the tube.
• Stranded wire (flat braided copper conductor): the figure given in the standard shows that the entire core is flattened and the core of several conductors is of the braided type.
• Ultrasonic wave joining (ultrasonic welding): A technique in which the conductors of multiple cables are joined by touching the unsheathed conductors together and then joining them with ultrasonic waves.
• Shield wire: It is a conductor that can cut off the noise coming from outside the conductor and is applied to reduce electromagnetic compatibility noise. There is a type with braided wire and aluminum sheet.
• High temperature sleeve: It is an outer material with reflective materials on the heat insulation materials to prevent thermal damage to cables passing through high temperature areas.
• Opening angle: It refers to the angle at which the door is fully opened, and the corresponding size is applied when the ring is designed.
• Installation range: The distance of the ring from the door panel and the area where the vehicle body panel is fixed.
• Tape cable: It is a tape strap that fixes cables by drilling holes to other parts.
• Clip: It is a part that fixes the cables by making holes in other parts and is fixed to the cables with additional tape.
• Corrugated tube: It is a cable protector with excellent bending performance due to the wavy wrinkles applied to its surface. It is a tube applied to a part where high wear resistance is desired.
• Ultrasonic welding grounding terminal: After removing the cable insulation of multiple grounding circuits, it is the terminal that aligns the conductivity of the cables with each other and welds them to the terminal by ultrasonic welding method.

As a general requirement, when a product is manufactured in accordance with a wiring engineering design drawing, approved standards for design, materials and processing and manufacturing techniques must be followed, and if a part of the approved product is changed, it must be tested and approved before production. The sample must be tested in accordance with this standard. If it does not meet any of the specified requirements, testing must be stopped.

The wiring supplier undertakes the responsibility of inspecting the performance and water-tight air-tightness of the new joint combination on a part where the heat shrink adhesive tube is applied, and submits the inspection report. This process is carried out once in the proto and pilot stages respectively. Before starting mass production, the test examination results are published together with the mass production quality assurance plan.

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