DIN 72036 (E) 2024-06 - Statistics of design rules Date of issue:

Summarization of all design rules

Chapter Rules Recommendations

A.1 Design rules for wiring harness concepts suitable for automated production 1 10

A.2 Design rules for wiring harness designs suitable for automated production 25 10

A.3 Design rules for manufacturing processes suitable for automated production 3 1

A.4 Design rules for components suitable for automated production 8 2

Total: 37 23

Allocation of the design rules Rules Recommendations

Vehicle wiring system 3 6

150% Wiring harness 16 6

Wiring harness 5 3

Partial wiring harness 13 8

Total: 37 23

Motivation of the design rules Rules Recommendations

Optimize variety 6 10

Enhance process 28 12

Improve product 3 1

Total 37 23

Register "Listing of all Design rules"

This register lists all design rules of the DIN 72036 in tabular form..
The rows are sorted according to the table number of the design rules.
The columns contain basic information on the design rules.
ð Changes or additions to the column contents can be communicated directly to the author named below.

Register "Matrix systematics"

In this register, all design rules of DIN 72036 are assigned to the core requirements for automatability.
All content are read with the SVERWEIS () function from the register “Listing of all Design rules”.
ð Changes or additions to the column contents can be communicated directly to the author named below.

Author of this excel file

Coroplast Fritz Müller GmbH & Co. KG

Helmut Wichmann
Director Global Product Management & Marketing
Wires & Cables

Wittener Straße 271

42279 Wuppertal, Germany
T +49 202 2681 155
F +49 202 2681 135
M +49 160 3659577
[email protected]
Wittener Straße 271
42279 Wuppertal, Germany
T +49 202 2681 155
F +49 202 2681 135
M +49 160 3659577
[email protected]
12/11/2024

Total

11

35

10

60

Total

22

21

60

Total

16

40

60
DIN 72036 (E) 2024-06 - Annex A: Design rules
Category Chapter ID Table

WH concept A.1.1 General 135067 A.1

WH concept A.1.1 General 345938 A.2

WH concept A.1.1 General 259959 A.3

WH concept A.1.1 General 689762 A.4

WH concept A.1.1 General 457158 A.5

WH concept A.1.1 General 890738 A.6

WH concept A.1.1 General 607707 A.7

WH concept A.1.2 Contact carrier 407527 A.8

WH concept A.1.3 Mounting parts 954795 A.9

WH concept A.1.4 Connection structure 615882 A.10

WH concept A.1.4 Connection structure 866354 A.11

WH design A.2.1 General 172486 A.12

WH design A.2.1 General 895198 A.13

WH design A.2.1 General 489200 A.14

WH design A.2.2 Mounting parts 770863 A.15

WH design A.2.2 Mounting parts 317887 A.16

WH design A.2.2 Mounting parts 714621 A.17

WH design A.2.2 Mounting parts 935584 A.18

WH design A.2.2 Mounting parts 260631 A.19

WH design A.2.2 Mounting parts 977843 A.20

WH design A.2.3 Terminals 524465 A.21

WH design A.2.3 Terminals 310735 A.22

WH design A.2.3 Terminals 290800 A.23

WH design A.2.3 Terminals 718108 A.24

WH design A.2.3 Terminals 593889 A.25

WH design A.2.4 Electrical cables 524350 A.26

WH design A.2.4 Electrical cables 478795 A.27

WH design A.2.4 Electrical cables 832197 A.28

WH design A.2.4 Electrical cables 092394 A.29

WH design A.2.4 Electrical cables 925040 A.30

WH design A.2.4 Electrical cables 384332 A.31

 WH design A.2.4 Electrical cables 948648 A.32

WH design A.2.4 Electrical cables 706757 A.33

WH design A.2.4 Electrical cables 571369 A.34

WH design A.2.5 Wire protection components 625267 A.35

WH design A.2.5 Wire protection components 546271 A.36

WH design A.2.5 Wire protection components 440108 A.37

WH design A.2.5 Wire protection components 159418 A.38

WH design A.2.6 Wire connectors 181916 A.39

WH design A.2.6 Wire connectors 617422 A.40

WH design A.2.6 Wire connectors 109085 A.41

WH design A.2.6 Wire connectors 830085 A.42

WH design A.2.7 Connection structure 546195 A.43

WH design A.2.7 Connection structure 619930 A.44

WH design A.2.7 Connection structure 958211 A.45

WH design A.2.7 Connection structure 427421 A.46

WH production A.3.1 Pre-assembly 504937 A.47

WH production A.3.1 Pre-assembly 183793 A.48

WH production A.3.1 Pre-assembly 952093 A.49

WH production A.3.2 Assembly process 160473 A.50

Component
A.4.1 Mounting parts 783439 A.51
specifications

Component
A.4.1 Mounting parts 969791 A.52
specifications

Component
A.4.1 Mounting parts 356993 A.53
specifications

Component
A.4.1 Mounting parts 136523 A.54
specifications

Component
A.4.2 Sealing elements 872352 A.55
specifications

Component
A.4.3 Terminals 476220 A.56
specifications

Component
A.4.3 Terminals 139563 A.57
specifications

Component
A.4.3 Terminals 106918 A.58
specifications

Component
A.4.4 Electrical cables 384361 A.59
specifications

Component
A.4.5 Connectors 056177 A.60
specifications
 Headline

WH concept — Define core requirement

for automation-friendly preselection of
process technology variety

WH concept — Define core requirement

for automation-friendly preselection of part
variety

WH concept — Define core requirement

for automation-friendly preselection for
connection

WH concept — Define core requirement

for designs suitable for automated
production

WH concept — Define core requirement

for components suitable for automated
production

WH concept — Define core requirement

for partial wiring harnesses suitable for
automated production

WH concept — Define core requirement

for product improvements

WH concept — Determine position of

terminals for UTP cables in contact carriers

WH concept — Use cable ducts suitable

for automated production

WH concept — Define connection

structures

WH concept —Avoid crossovers of

electrical cables

WH design — Use wiring harness

components suitable for automated
production

WH design — Design non-electrical lines

as closed additional partial wiring
harnesses

WH design — Design electrical cables,

other than single-core and UTP cables, as
terminated additional partial wiring
harnesses

WH design — Define accessibility for

positioning clips
WH design —Use feed-through grommets
suitable for automated production

WH design — Define part variety of clips in

150 % wiring harness

WH design — Define part variety of clips in

partial wiring harnesses

WH design — Define process technology

variety of clips

WH design — Define routing path of lines

in foam grommets

WH design — Define the variety of

terminals and single wire seals

WH design — Define number of cores on

terminals and cable lugs

WH design — Define process technology

variety for terminals and cable lugs

WH design — Define automation-friendly

contacting of crimp cable lugs

WH design — Define heat shrink tubing

suitable for automated production

WH design — Determine cable lengths of

single-core cables

WH design — Define ISO conductor sizes

of single-core cables

WH design — Define cable lengths of UTP

cables

WH design — Define ISO conductor sizes

for twisted cores

WH design — Define characteristics for

optical differentiation of the cores of UTP
cables

WH design — Use automation-friendly

stranded conductors
WH design — Determine automation-
friendly conductor material combination

WH design — Define machine-friendly

specifications for pinning of UTP cables

WH design — Define variants of ISO

conductor sizes and cable types of
electrical cables

WH design — Determine variants of wire

protection components

WH design — Use wire protection

components suitable for automated
production

WH design — Define process technology

variety for wire protection systems

WH design — Determine accessibility for

taping

WH design — Define wire connector

design types

WH design — Define process technology

variety for end splices

WH design — Define number of cores for

end splices

WH design — Define sealing or electrical

insulation of end splices

WH design — Define connection depth

WH design — Define variety of meshing

WH design — Define number of contact

carriers in partial wiring harnesses

WH design — Define number of cores in

partial wiring harnesses

WH production — Define joining process

for terminals
WH production — Define deformation of
terminals during crimping

WH production — Define pinning

requirements

WH production — Define geometric routing

paths for production

Component — Define cover caps for

connector housing

Component — Determine outer geometry

of foam grommets

Component — Determine cross-sectional

geometry of foam grommets

Component — Determine wall thickness of

foam grommets

Component — Determine geometry of

single wire seals

Component — Perform measurement of

the nominal terminal cross-section
combination during crimping

Component — Define terminal supply for

crimping tools

Component — Define supply of terminals

Component — Define suitability for

straightening of single-core cables

Component — Determine the variety of

cavity sizes of contact carriers
 Design rule

The process technologies used to produce the wiring harness/partial wiring harness (see references to
concretizations in this design rule) shall be defined to a level of technical characteristics that can be automated.

The components used in the wiring harness/partial wiring harness (see references to concretizations in this design
rule) shall each be defined to a level of technical characteristics that can be automated.

The vehicle wiring system network shall be realized by means of self-contained partial wiring harnesses which fulfil
the specifications of the production line (see references to specifications in this design rule).

The design of the wiring harness shall be matched to the requirements of the available process technology suitable
for automated production (see references to concretizations in this design rule).

The components used in the wiring harness shall comply with the design rules (see references to concretizations in
this design rule).

Excessively large and complex partial wiring harnesses lead to complex production solutions. An automated
production solution cannot be implemented universally.

The processes for producing a wiring harness shall ensure quality specifications.

For the cores of UTP cables, the position of the cavities and the primary locks in the contact carriers shall meet
defined requirements.

Cable ducts shall be designed for the automated production of wiring harnesses.

The connection structures of the wiring harness shall meet defined requirements with regard to the design of the
connections.

The connections between contact carriers of a partial wiring harness shall meet defined requirements with regard to
pin assignment.

No components shall be used that do not comply with the design rules categorized as a rule in Clause A.4 in order to
achieve interoperability of components with an automated production line.

The integration of non-electrical lines into the wiring harness shall meet defined design requirements.

The integration of electrical cables, other than single-core and UTP cables, into the wiring harness shall meet defined
design requirements.

Accessibility to the clips positioned on a wiring harness shall be guaranteed. This applies to clips regardless of the
type of fastening.
Feed-through grommets shall be suitable for automated production.

The number of possible different clips shall be defined in the 150 % wiring harness.

The number of possible different clips shall be defined in the partial wiring harness.

The number of different processes for attaching the clip to the wiring harness shall be specified in the 150 % wiring
harness.

The routing path and the contour of the wiring segment in the foaming area shall meet certain requirements in terms
of three-dimensional routing.

The partial wiring harness shall meet defined requirements regarding the terminal and SWS variants.

The number of possible cores on a terminal or cable lug shall meet defined requirements.

The number of process technologies for joining the cores of the electrical cables with terminals or cable lugs shall be
specified in the partial wiring harness.

Only cable lugs for crimping without additional soldering should be used.

Heat shrink tubing shall be suitable for automated production.

For an automation-friendly and interoperable design of production lines, the cable length of single-core cables shall
not fall below or exceed defined limit values.

The ISO conductor size of the single-core cables shall not fall below or exceed defined limit values.

For an automation-friendly and interoperable design of production lines, the cable length of UTP cables shall not fall
below or exceed defined limit values.

The twisted wires used in a partial wiring harness shall be within a range for ISO conductor sizes.

The individual cores of UTP cables shall be visually distinguishable.

The stranded conductor shall not be subsequently treated by tin coating.

In partial wiring harnesses, aluminium and copper cables shall not be processed together.

There shall be sufficient area for gripping the UTP cable cores to ensure the automated pinning of UTP cables.

The number of different ISO conductor sizes for each used cable type shall be as specified.

The number of types of wire protection components used (e.g. tape, corrugated tube, smooth tube) shall be specified
in the wiring harness.

Wire protection components for the production of wiring harnesses in longitudinal direction shall be provided in a non-
closed or otherwise optimized design for automated production.

Wire protection systems that require different process technologies should not be combined.

A defined minimum distance shall be maintained between two neighbouring branch points to ensure access to the
wiring segment with a tape applicator.

Possible types of wire connectors shall be specified.

The joining process for end splices shall be designed for the automated production of wiring harnesses.

The possible number of cores of an end splice shall be defined in the partial wiring harness.

End splices shall be sealed or electrically insulated against malfunction and environmental influences. Threading
processes for sealing or insulating end splices shall be designed for the automated production of wiring harnesses.

A partial wiring harness shall meet defined requirements in terms of connection depth.

A connection structure shall fulfil defined requirements with regard to meshes in partial wiring harnesses.

Each partial wiring harness shall meet defined requirements regarding the possible number of contact carriers.

A partial wiring harness shall meet defined requirements with regard to the possible number of single-core cables.
For multi-core cables, the number of cores of the multi-core cables is counted (for example, a UTP cable consists of
two cores).

Only terminals of the same joining process (e.g. crimping) should be used in a partial wiring harness.
The torsion and deformation of a terminal along the longitudinal axis of the core shall not exceed specified limits.

The core shall be able to transmit the force required for pinning a terminal into a contact carrier without buckling.

It shall be possible to transfer the branches at a node and the 3D routing path to the geometry of the assembly board.
In a node, branches may only emerge in the 2D plane of the assembly board.

Cover caps for connector housings shall be of a type suitable for automated processing.

The geometry of a foam grommet shall meet defined requirements.

The cross-sectional geometry of a foam grommet shall be designed in such a way that the wiring segments are
completely enclosed in the lower half of the mould.

The wall thickness between the wiring segment and the outer wall of the foam grommet shall meet defined
specifications.

The SWS and the terminal should be connected and not be able to come loose. For this purpose, the SWS should
have a collar or another suitable shape.

The requirement regarding failure detection during the crimping process shall be met.

For processing with crimping tools, the terminals shall be unwound from reels as “left entering”.

Only belted terminals or terminals on the carrier strip on reels should be used.

Use single-core cables that are easy to straighten.

The number of different cavity sizes in a contact carrier shall be specified.

 Requirements as a target value Measurement criterion Liability

Without target value Without measurement criterion Recommendation

Without target value Without measurement criterion Recommendation

Without target value Without measurement criterion Recommendation

Without target value Without measurement criterion Recommendation

Without target value Without measurement criterion Recommendation

Without target value Without measurement criterion Recommendation

Without target value Without measurement criterion Recommendation

Cavities for the cores of the core pair are arranged

directly adjacent = 100 %
Evaluate digital product descriptions Rule
Arrangement types and orientation of the cavities =
1 (all horizontal (recommendation) or all vertical)

Cable ducts suitable for automated production in the

Evaluate digital product descriptions Recommendation
wiring harness = 100 %

Connection type “point-to-point connection” of

Evaluate digital product descriptions Recommendation
electrical cables = 100 %

There shall be a position variant for the contact

carriers that represents a geometrically analogue
Evaluate digital product descriptions Recommendation
pin assignment which results in cable routing
without crossovers.

Application of the rules from Clause A.4 = 100 % Evaluate digital product descriptions Rule

Non-electrical lines shall be designed as self-

contained partial wiring harnesses that are suitable Evaluate digital product descriptions Rule
for automated production.

Electrical cables other than single-core and UTP

cables shall be designed as self-contained partial Evaluate digital product descriptions Rule
wiring harnesses.
Distance between the clip and the neighbouring
interference contour (distance l1) ≥ 45 mm
Distance around the wiring segment (distance l2 a))
≥ 90 mm Evaluate digital product descriptions Recommendation
a) Dimension cannot be checked in the WH design
and depends on the production of the wiring
harness.
Feed-through grommets suitable for automated
Evaluate digital product descriptions Rule
production = 100 %

Sum of different part numbers in the 150 % wiring

Evaluate digital product descriptions Recommendation
harness for clips ≤ 30

Sum of different part numbers in a partial wiring

Evaluate digital product descriptions Recommendation
harness for clips ≤ 5

Number of process technologies for attaching clips

Evaluate digital product descriptions Rule
=1

Routing path of the wiring segment in foam

Evaluate digital product descriptions Recommendation
grommets in a 2D plane = 100 %

Sum of different part numbers of terminals and

Evaluate digital product descriptions Rule
SWSs ≤ 8

Number of cores on terminal or cable lug = 1 Evaluate digital product descriptions Rule

Number of process technologies for contacting

cores with terminals or cable lugs in partial wiring Evaluate digital product descriptions Recommendation
harnesses = 1

Number of process technologies for crimping crimp

Evaluate digital product descriptions Rule
cable lugs with soldering = 0

Heat shrink tubing suitable for automated production

Evaluate digital product descriptions Rule
= 100 %

DMU length of single-core cables ≥ 0,4 m

Evaluate digital product descriptions Rule
DMU length of single-core cables ≤ 3,5 m

ISO conductor size of single-core cables ≥ 0,13

mm2 Evaluate digital product descriptions Rule
ISO conductor size of single-core cables ≤ 2,5 mm2

DMUtolength
Due of UTPtechnology,
the process cables ≥ 0,4which
m depends on
Evaluate digital product descriptions Rule
DMU
the length
ISO of UTPsize,
conductor cables
the ≤target
3,5 mvalue requires
two ISO conductor size areas, each of which can be
processed by one process technology.
ISO conductor size area 1:
ISO conductor size of twisted cores ≥ 0,35 mm2
Evaluate digital product descriptions Rule
ISO conductor size of twisted cores ≤ 2,5 mm2
ISO conductor size area 2:
ISO conductor size of twisted cores ≥ 0,13 mm2
ISO conductor
Cores of a coresize
pairofhave
twisted cores ≤ 0,5 colours
distinguishable mm2 =
Number
100 % of ISO conductor size areas used in a
partial Evaluate digital product descriptions Rule
Colourswiring
of theharness
cores of=a1core pair are monochrome
= 100 %

Number of process technologies with stranded

Evaluate digital product descriptions Rule
conductors to be subsequently tin-coated = 0
Number of metals of the conductor materials = 1 Evaluate digital product descriptions Rule

Accessible core length for gripper (length l4) of each

Evaluate digital product descriptions Rule
UTP cable core ≥ 8 mm

table (ISO conductor sizes 0,13 - 2,5 mm²)

Evaluate digital product descriptions Recommendation
Number of cable types = 1

Number of types of wire protection components

used in a wiring harness ≤ 2
Evaluate digital product descriptions Rule
Number of part numbers of the wire protection
components in a wiring harness ≤ 5

Wire protection components suitable for automated

Evaluate digital product descriptions Rule
production = 100 %

Number of process technologies for attaching the

Evaluate digital product descriptions Recommendation
wire protection components = 1
Distance between the end of the winding section
and the interference contour on one side (distance
l1) ≥ 15 mm and on the other side (distance l2) ≥ 40
mm
Distance around the wiring segment (distance l3a)) Evaluate digital product descriptions Recommendation
≥ 90 mm
a) Dimension cannot be checked in the WH design
and depends on the production of the wiring
harness.
Splice is end splice = 100 % Evaluate digital product descriptions Rule

End splices suitable for automated production = 100

% Evaluate digital product descriptions Rule
Technologies for end splices = 1

Number of cores of each end splice ≤ 10 Evaluate digital product descriptions Rule

Sealing or electrical insulation of end splices

suitable for automated production = 100 %
Evaluate digital product descriptions Rule
Technologies for sealing or electrical insulation of
end splices = 1

Connection depth of the tree structure ≤ 6 Evaluate digital product descriptions Recommendation

Number of exposed edges per elementary mesh ≥ 1 Evaluate digital product descriptions Rule

Number of contact carriers in the partial wiring

Evaluate digital product descriptions Rule
harness ≤ 20

Number of cores in a partial wiring harness ≤ 50 Evaluate digital product descriptions Recommendation

Terminal data sheet

Number of process technologies for joining
Specification in the wiring harness Rule
terminals = 1
drawing and bill of materials
Bending in elevation < 5 °
Bending in plan < 3 ° Angle measurement after crimping Rule
Torsion around the longitudinal axis < 5 °

Process reliability cannot be reliably

Successfully passing the pinning test with the proven numerically but is based on
Rule
specific components. pinning tests with the specific
components.

Routing path of the wiring segment has radial

Installation test Recommendation
branches in a 2D plane during production = 100 %

Caps suitable for automated production = 100 % Bill of materials analysis Rule

Number of undercuts for foam grommets = 0 Drawing evaluation Rule

Ratio of leg length (distance S) of the lower tool half

to the diameter of the wiring segment (distance d) Drawing evaluation Rule
S / d ≥ 1,2

Wall thickness of the foam grommet (distance L)

Drawing evaluation Rule
L ≥ 5 mm

Single-wire seal with collar (or other suitable

contour) for cores (with ISO conductor size ≤ 2,5 SWS data sheet Rule
mm2) = 100 %

Headroom according to PG 60, TLF 0214 (ZVEI

Processing test Recommendation
Technical Guidelines) fulfilled = 100 %

Crimping tools have left-sided entry with terminals

Terminal drawing Rule
on reels = 100 %

Terminals belted or on carrier strip, with paper inlay

Data sheet Rule
on reels = 100 %

Single-core cables are approved for automated

Production release Recommendation
production = 100 %

Number of different cavity sizes per contact carrier ≤ Number of different cavity sizes
Rule
3 according to data sheet.
 Date of issue:

Component(s) Process Wiring harness level

component-independent all processes Vehicle wiring system

all components process-independent Vehicle wiring system

component-independent process-independent Vehicle wiring system

component-independent all processes Vehicle wiring system

all components process-independent Vehicle wiring system

component-independent process-independent Partial wiring harness

all components all processes Vehicle wiring system

contact carrier pinning Vehicle wiring system

cable duct assembly process 150% Wiring harness

component-independent process-independent 150% Wiring harness

component-independent process-independent Partial wiring harness

all components process-independent Vehicle wiring system

non-electrical lines assembly process Partial wiring harness

electrical cables, deviating from single-

assembly process Partial wiring harness
core and UTP cables

clip assembly process – fixing the tape clips Wiring harness

 feed-through grommets assembly process 150% Wiring harness

clip process-independent 150% Wiring harness

clip process-independent Partial wiring harness

clip, (tape) assembly process 150% Wiring harness

foam grommets foaming 150% Wiring harness

terminal, single wire seal (SWS) pre-assembly Partial wiring harness

terminal, cable lug pre-assembly - crimping 150% Wiring harness

terminal, cable lug pre-assembly Partial wiring harness

crimp cable lug pre-assembly 150% Wiring harness

heat shrink tubing pre-assembly 150% Wiring harness

single-core cable pre-assembly - cutting 150% Wiring harness

single-core cable pre-assembly 150% Wiring harness

UTP cable pre-assembly - cutting 150% Wiring harness

twisted cores pre-assembly Partial wiring harness

UTP cable pre-assembly 150% Wiring harness

electrical cable pre-assembly 150% Wiring harness

 electrical conductor(s) pre-assembly Partial wiring harness

contact carrier, UTP cable pinning 150% Wiring harness

electrical cable process-independent 150% Wiring harness

wire protection component assembly process Wiring harness

wire protection component assembly process 150% Wiring harness

wire protection component assembly process 150% Wiring harness

tape assembly process Wiring harness

electrical cable, wire connector pre-assembly 150% Wiring harness

electrical cable, wire connector pre-assembly 150% Wiring harness

electrical cable, wire connector pre-assembly Partial wiring harness

end splice, end cap pre-assembly – insulation or sealing Partial wiring harness

component-independent process-independent Partial wiring harness

component-independent process-independent Partial wiring harness

contact carrier, connector housing process-independent Partial wiring harness

single-core cable, UTP cable process-independent Partial wiring harness

electrical cable, terminal pre-assembly – attach terminal Partial wiring harness

 terminal pre-assembly – attach terminal Partial wiring harness

electrical cable, seal, terminal and others pinning Partial wiring harness

component-independent assembly process Wiring harness

cover cap for connector housing assembly process Wiring harness

foam grommets foaming Wiring harness

foam grommets foaming Wiring harness

foam grommets foaming Wiring harness

single wire seal (SWS) pre-assembly Partial wiring harness

electrical cable, terminal, cable lug stripping and crimping Partial wiring harness

terminal pre-assembly – attach terminal Vehicle wiring system

terminal pinning 150% Wiring harness

electrical cable pre-assembly – cutting Partial wiring harness

contact carrier pre-assembly 150% Wiring harness

 12/11/2024

Motivation

Optimize variety

Optimize variety

Optimize variety

Enhance process

Enhance process

Enhance process

Improve product

Enhance process

Enhance process

Optimize variety

Enhance process

Enhance process

Enhance process

Enhance process

Enhance process
Enhance process

Optimize variety

Optimize variety

Optimize variety

Enhance process

Optimize variety

Enhance process

Optimize variety

Enhance process

Enhance process

Enhance process

Enhance process

Enhance process

Enhance process

Enhance process

Enhance process
Improve product

Enhance process

Optimize variety

Enhance process

Enhance process

Enhance process

Enhance process

Enhance process

Enhance process

Enhance process

Enhance process

Optimize variety

Optimize variety

Optimize variety

Optimize variety

Optimize variety
Improve product

Enhance process

Enhance process

Enhance process

Enhance process

Enhance process

Enhance process

Improve product

Enhance process

Optimize variety

Enhance process

Enhance process

Enhance process
DIN 72036 (E) 2024-06 - Annex A: Design rules
Wiring harness concept
Core requirements for
automatability
ID table Liability Wiring harness level

135067 A.1 Recommendation Vehicle wiring system

Pre-Selection of
process technology variety

345938 A.2 Recommendation Vehicle wiring system

Optimize variety

Pre-Selection of
part variety

259959 A.3 Recommendation Vehicle wiring system

615882 A.10 Recommendation 150% Wiring harness

Pre-Selection of
connection

689762 A.4 Recommendation Vehicle wiring system

890738 A.6 Recommendation Partial wiring harness

866354 A.11 Recommendation Partial wiring harness

Designs suitable for

automated production
Enhance process
Enhance process

457158 A.5 Recommendation Vehicle wiring system

407527 A.8 Rule Vehicle wiring system

954795 A.9 Recommendation 150% Wiring harness

Components suitable for

automated production

607707 A.7 Recommendation Vehicle wiring system

Improve product

Wiring harness
processes and
components

Wiring harness
installation
Wiring harness concept Wiring harness de

Headline ID table Liability

WH concept — Define core requirement for automation-friendly
260631 A.19 Rule
preselection of process technology variety

290800 A.23 Recommendation

WH concept — Define core requirement for automation-friendly

714621 A.17 Recommendation
preselection of part variety

935584 A.18 Recommendation

524465 A.21 Rule

571369 A.34 Recommendation

WH concept — Define core requirement for automation-friendly

546195 A.43 Recommendation
preselection for connection

WH concept — Define connection structures 619930 A.44 Rule

958211 A.45 Rule

427421 A.46 Recommendation

WH concept — Define core requirement for designs suitable for

172486 A.12 Rule
automated production
WH concept — Define core requirement for partial wiring harnesses
895198 A.13 Rule
suitable for automated production

WH concept —Avoid crossovers of electrical cables 489200 A.14 Rule

770863 A.15 Recommendation

317887 A.16 Rule

977843 A.20 Recommendation

310735 A.22 Rule

718108 A.24 Rule

593889 A.25 Rule

524350 A.26 Rule

478795 A.27 Rule

832197 A.28 Rule

092394 A.29 Rule

925040 A.30 Rule

384332 A.31 Rule

706757 A.33 Rule

 625267 A.35 Rule

546271 A.36 Rule

440108 A.37 Recommendation

159418 A.38 Recommendation

181916 A.39 Rule

617422 A.40 Rule

109085 A.41 Rule

830085 A.42 Rule

WH concept — Define core requirement for components suitable for

automated production
WH concept — Determine position of terminals for UTP cables in
contact carriers

WH concept — Use cable ducts suitable for automated production

WH concept — Define core requirement for product improvements 948648 A.32 Rule
 Wiring harness design C

Wiring harness level Headline ID table

150% Wiring harness WH design — Define process technology variety of clips

WH design — Define process technology variety for terminals and

Partial wiring harness
cable lugs

150% Wiring harness WH design — Define part variety of clips in 150 % wiring harness 139563 A.57

Partial wiring harness WH design — Define part variety of clips in partial wiring harnesses

Partial wiring harness WH design — Define the variety of terminals and single wire seals

WH design — Define variants of ISO conductor sizes and cable types

150% Wiring harness
of electrical cables

Partial wiring harness WH design — Define connection depth

Partial wiring harness WH design — Define variety of meshing

WH design — Define number of contact carriers in partial wiring

Partial wiring harness
harnesses

Partial wiring harness WH design — Define number of cores in partial wiring harnesses

WH design — Use wiring harness components suitable for automated

Vehicle wiring system
production
WH design — Design non-electrical lines as closed additional partial
Partial wiring harness
wiring harnesses
WH design — Design electrical cables, other than single-core and UTP
Partial wiring harness
cables, as terminated additional partial wiring harnesses

Wiring harness WH design — Define accessibility for positioning clips

WH design —Use feed-through grommets suitable for automated

150% Wiring harness
production

150% Wiring harness WH design — Define routing path of lines in foam grommets

150% Wiring harness WH design — Define number of cores on terminals and cable lugs

150% Wiring harness WH design — Define automation-friendly contacting of crimp cable lugs

WH design — Define heat shrink tubing suitable for automated

150% Wiring harness
production

150% Wiring harness WH design — Determine cable lengths of single-core cables

150% Wiring harness WH design — Define ISO conductor sizes of single-core cables

150% Wiring harness WH design — Define cable lengths of UTP cables

Partial wiring harness WH design — Define ISO conductor sizes for twisted cores

WH design — Define characteristics for optical differentiation of the

150% Wiring harness
cores of UTP cables

150% Wiring harness WH design — Use automation-friendly stranded conductors

WH design — Define machine-friendly specifications for pinning of UTP

150% Wiring harness
cables
 Wiring harness WH design — Determine variants of wire protection components

WH design — Use wire protection components suitable for automated

150% Wiring harness
production
WH design — Define process technology variety for wire protection
150% Wiring harness
systems

Wiring harness WH design — Determine accessibility for taping

150% Wiring harness WH design — Define wire connector design types

150% Wiring harness WH design — Define process technology variety for end splices

Partial wiring harness WH design — Define number of cores for end splices

Partial wiring harness WH design — Define sealing or electrical insulation of end splices

783439 A.51

969791 A.52

356993 A.53

136523 A.54

476220 A.56

106918 A.58

384361 A.59

056177 A.60

WH design — Determine automation-friendly conductor material

Partial wiring harness 872352 A.55
combination
 Component specifications

Liability Wiring harness level Headline ID

504937

Rule Vehicle wiring system Component — Define terminal supply for crimping tools

952093

160473
 Rule Wiring harness Component — Define cover caps for connector housing

Rule Wiring harness Component — Determine outer geometry of foam grommets

Rule Wiring harness Component — Determine cross-sectional geometry of foam grommets

Rule Wiring harness Component — Determine wall thickness of foam grommets

Component — Perform measurement of the nominal terminal cross-

Recommendation Partial wiring harness
section combination during crimping

Rule 150% Wiring harness Component — Define supply of terminals

Recommendation Partial wiring harness Component — Define suitability for straightening of single-core cables

Rule 150% Wiring harness Component — Determine the variety of cavity sizes of contact carriers

Rule Partial wiring harness Component — Determine geometry of single wire seals 183793
 Date of issue: 11/12/2024
Wiring harness production

table Liability Wiring harness level Headline

A.47 Rule Partial wiring harness WH production — Define joining process for terminals

A.49 Rule Partial wiring harness WH production — Define pinning requirements

A.50 Recommendation Wiring harness WH production — Define geometric routing paths for production
A.48 Rule Partial wiring harness WH production — Define deformation of terminals during crimping