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R26 A方案第一版线束制造表与BOM

制造边界：ECU端壳体、端子、密封塞与工具已经可以落实到具体物料号；但设备端连接器、实际线长、最终AWG和保险安培值仍要等待传感器/阀型号、整机布置和实机路径测量后冻结。

R26 harness manufacturing BOM architecture

一、ECU连接器、端子、密封塞和工具BOM

BOM ID项目厂家物料号说明数量状态
CON-RES-01MC050 ECU mating connectorDanfoss / DEUTSCH1010202450-pin mating connector bag assembly, 16–20 AWG1VERIFIED_CANDIDATE
CON-RES-02MC050 alternate fine-wire kitDanfoss / DEUTSCH1010094650-pin mating connector bag assembly, 20–24 AWG0/1 alternativeVERIFIED_ALTERNATIVE
CON-RES-03MC050 connector shellDEUTSCHDRC26-50S0150-position DRC mating plug per Danfoss family technical informationincluded in bag / service referenceVERIFIED_REFERENCE
CON-CHS-01MC024 ECU mating connector pairDanfoss / DEUTSCH101020232 x DTM06 12-socket A/B keyed, 16–20 AWG1 bagVERIFIED_CANDIDATE
CON-CHS-02MC024 alternate fine-wire kitDanfoss / DEUTSCH101009452 x DTM06 12-socket A/B keyed, 20–24 AWG0/1 alternativeVERIFIED_ALTERNATIVE
CON-CHS-03MC024 connector shellsDEUTSCHDTM06-12SA / DTM06-12SBGray A-key / Black B-key 12-position plugs1 eachVERIFIED_REFERENCE
CON-SAF-01SC024 ECU mating connector pairDanfoss / DEUTSCH1010202324-pin module mating bag, 16–20 AWG1 bagVERIFIED_CANDIDATE
CON-SAF-02SC024 alternate fine-wire kitDanfoss / DEUTSCH1010094524-pin module mating bag, 20–24 AWG0/1 alternativeVERIFIED_ALTERNATIVE
CON-TERM-0120–24 AWG solid socket contactDEUTSCH0462-201-2031Socket contact referenced by Danfoss SC family TIAS_REQUIREDVERIFIED_REFERENCE
CON-TERM-0216–20 AWG stamped socket contactDEUTSCH1062-20-0144Stamped socket contact referenced by Danfoss SC family TIAS_REQUIREDVERIFIED_REFERENCE
CON-SEAL-01Unused cavity sealing plugDEUTSCH0413-204-2005Sealing plug for unused cavitiesAS_REQUIREDVERIFIED_REFERENCE
CON-WEDGE-01DTM wedge lockDEUTSCHWM-12S12-position socket wedge lock2 per 24-pin ECU pairVERIFIED_REFERENCE
TOOL-CRIMP-01Crimp tool 20–24 AWGDanfoss/DEUTSCH10100745 / HDT48-00 referenceCrimp tool for fine-wire solid contactsshop toolingVERIFIED_REFERENCE
TOOL-CRIMP-02Crimp tool 16–20 AWGDanfoss/DEUTSCH10102028 / DTT20-00 referenceCrimp tool for stamped contactsshop toolingVERIFIED_REFERENCE
TOOL-EXT-01Contact extraction toolDanfoss/DEUTSCH10100744 / 0411-240-2005Extraction tool for 16–20 / 20–24 AWG contactsshop toolingVERIFIED_REFERENCE

二、线束制造线表

所有线长保持 TBD_MEASURE_ON_CHASSIS，生产放行前必须沿真实路径测量并加入弯曲、应变释放和维修余量。

线号端点A端点B功能线色线径初选长度区域说明
W-S01pickup speed sensorMC050 C1-P25S01 pickup speedBU20 AWG candidateTBD_MEASURE_ON_CHASSISH1twisted/shielded if sensor/manual requires
W-S02main conveyor speed sensorMC050 C1-P26S02 conveyor speedBU20 AWG candidateTBD_MEASURE_ON_CHASSISH6used by PRE_BLOCK/BLOCK
W-S03hydraulic inlet pressure sensorMC050 C1-P23S03 inlet pressureGY20 AWG candidateTBD_MEASURE_ON_CHASSISH64–20 mA requires conditioner/shunt design
W-S04hydraulic outlet pressure sensorMC050 C1-P24S04 outlet pressureGY20 AWG candidateTBD_MEASURE_ON_CHASSISH64–20 mA requires conditioner/shunt design
W-S05coarse cutter speed sensorMC050 C1-P27S05 coarse cutter speedBU20 AWG candidateTBD_MEASURE_ON_CHASSISH1
W-S06fine shredder speed sensorMC050 C1-P28S06 fine shredder speedBU20 AWG candidateTBD_MEASURE_ON_CHASSISH1
W-S07fan speed sensorMC050 C1-P29S07 fan speedBU20 AWG candidateTBD_MEASURE_ON_CHASSISH2
W-S08fan load transducer / driveMC050 C1-P30S08 load feedbackBU20 AWG candidateTBD_MEASURE_ON_CHASSISH1CAN alternative allowed
W-S09hood position sensorMC050 C1-P18S09 hood positionWH20 AWG candidateTBD_MEASURE_ON_CHASSISH2closed-loop mode confirmation
W-S10collection chamber pressure sensorMC050 C1-P19S10 chamber pressureWH20 AWG candidateTBD_MEASURE_ON_CHASSISH2
W-S11bin load/level conditionerMC050 C1-P31S11 bin load/levelWH20 AWG candidateTBD_MEASURE_ON_CHASSISH3raw bridge load cell requires amplifier
W-S12IMU/inclinometerMC024 C1-P3/P4 CANS12 roll/pitchYEtwisted CAN pairTBD_MEASURE_ON_CHASSISH6direct analog alternative not frozen
W-S13Lleft leveling position sensorMC024 C1-P10S13 left positionWH20 AWG candidateTBD_MEASURE_ON_CHASSISH6
W-S13Rright leveling position sensorMC024 C1-P11S13 right positionWH20 AWG candidateTBD_MEASURE_ON_CHASSISH6
W-S14wheel/track speed sensorMC024 C1-P12S14 local vehicle speedBU20 AWG candidateTBD_MEASURE_ON_CHASSISH4GNSS speed may also arrive via CAN
W-S15Aguard switch channel ASC024 C1-P12S15 guard AOG18 AWG candidateTBD_MEASURE_ON_CHASSISH5final diagnostic wiring per safety design
W-S15Bguard switch channel BSC024 C2-P1S15 guard BOG18 AWG candidateTBD_MEASURE_ON_CHASSISH5final diagnostic wiring per safety design
W-S16AE-stop channel ASC024 C1-P10S16 E-stop AOG18 AWG candidateTBD_MEASURE_ON_CHASSISH5independent safety chain
W-S16BE-stop channel BSC024 C1-P11S16 E-stop BOG18 AWG candidateTBD_MEASURE_ON_CHASSISH5independent safety chain
W-A01MC050 C1-P41feed proportional valve/driverA01 feed speedBN16 AWG candidateTBD_MEASURE_ON_CHASSISH1final by coil current/length
W-A02MC050 C1-P42conveyor proportional directional driverA02 conveyor commandBN16 AWG candidateTBD_MEASURE_ON_CHASSISH6two-coil valve needs extra physical output or local driver
W-A03MC050 C1-P43roller-gap actuator/valveA03 gap commandBN16 AWG candidateTBD_MEASURE_ON_CHASSISH6
W-A04MC050 C1-P44coarse cutter driver/valveA04 coarse cutterBN16 AWG candidateTBD_MEASURE_ON_CHASSISH1ECU output is command, not main motor power
W-A05MC050 C1-P45fine shredder driver/valveA05 fine shredderBN16 AWG candidateTBD_MEASURE_ON_CHASSISH1ECU output is command, not main motor power
W-A06MC050 C1-P46fan driver/valveA06 fan speedBN16 AWG candidateTBD_MEASURE_ON_CHASSISH2ECU output is command, not fan motor power
W-A07AMC050 C1-P33hood valve/actuator AA07 hood AGY16 AWG candidateTBD_MEASURE_ON_CHASSISH2paired output loading must be checked
W-A07BMC050 C1-P34hood valve/actuator BA07 hood BGY16 AWG candidateTBD_MEASURE_ON_CHASSISH2paired with C1-P33
W-A08AMC050 C1-P35vent actuator openA08 vent openGY16 AWG candidateTBD_MEASURE_ON_CHASSISH2paired output loading must be checked
W-A08BMC050 C1-P36vent actuator closeA08 vent closeGY16 AWG candidateTBD_MEASURE_ON_CHASSISH2paired with C1-P35
W-A09MC050 C1-P37cross conveyor local driverA09 cross conveyorGY16 AWG candidateTBD_MEASURE_ON_CHASSISH3external motor driver required for high-power electric motor
W-A10MC050 C1-P38bin unload local sequencer/valveA10 unloadGY16 AWG candidateTBD_MEASURE_ON_CHASSISH3bidirectional actuator may require extra output/local node
W-A11LMC024 C2-P3left leveling spoolA11 left levelingBN16 AWG candidateTBD_MEASURE_ON_CHASSISH4
W-A11RMC024 C2-P4right leveling spoolA11 right levelingBN16 AWG candidateTBD_MEASURE_ON_CHASSISH4C2-P5/P6 reserved if 4-corner leveling adopted
W-A12MC050 C1-P39alarm lamp/horn relayA12 alarmGY16 AWG candidateTBD_MEASURE_ON_CHASSISH6use relay/driver if load exceeds output limits
W-SAFE-ASC024 C2-P9hazardous-drive enable ASafety Enable AOG18 AWG candidateTBD_MEASURE_ON_CHASSISH5final safety architecture validation required
W-SAFE-BSC024 C2-P10hazardous-drive enable BSafety Enable BOG18 AWG candidateTBD_MEASURE_ON_CHASSISH5final safety architecture validation required
W-CANA-HCAN-A backbone nodeMC050 C1-P3 / MC024 C1-P3 / VCUCAN-A HighYE20 AWG twisted-pair candidateTBD_ROUTE_MEASUREH2/H4/H6Twist with W-CANA-L; 120 ohm termination only at backbone ends.
W-CANA-LCAN-A backbone nodeMC050 C1-P4 / MC024 C1-P4 / VCUCAN-A LowGN20 AWG twisted-pair candidateTBD_ROUTE_MEASUREH2/H4/H6Twist with W-CANA-H; no star topology.
W-RES-PWRF-ECU-RESMC050 C1-P2/P47/P48/P49/P50RES ECU +24 V power pinsRD16–18 AWG candidate per total ECU sourcing/return designTBD_ROUTE_MEASUREH2All device power supply + pins must be connected as required by Danfoss data sheet.
W-RES-GNDGND-ECUMC050 C1-P1RES ECU groundBK16–18 AWG candidateTBD_ROUTE_MEASUREH2Dedicated low-impedance return; do not substitute random chassis joint.
W-CHS-PWRF-ECU-CHSMC024 C1-P2/C2-P11/C2-P12CHS ECU +24 V power pinsRD18 AWG candidateTBD_ROUTE_MEASUREH4All MC024 power supply + pins must be connected as required by data sheet.
W-SAF-PWRF-SAFESC024 C1-P2Safety ECU +24 V independent branchRD18 AWG candidateTBD_ROUTE_MEASUREH5Independent protected branch; final safety architecture controls redundancy/diagnostics.

三、项目线色规则

代码颜色用途属性
RDRed24 V powerGAKI_PROJECT_CONVENTION_NOT_EXTERNAL_STANDARD
BKBlackpower/sensor return as designatedGAKI_PROJECT_CONVENTION_NOT_EXTERNAL_STANDARD
VTVioletregulated sensor supplyGAKI_PROJECT_CONVENTION_NOT_EXTERNAL_STANDARD
YEYellowCAN HighGAKI_PROJECT_CONVENTION_NOT_EXTERNAL_STANDARD
GNGreenCAN LowGAKI_PROJECT_CONVENTION_NOT_EXTERNAL_STANDARD
WHWhiteanalog sensor signalGAKI_PROJECT_CONVENTION_NOT_EXTERNAL_STANDARD
BUBluefrequency/digital process inputGAKI_PROJECT_CONVENTION_NOT_EXTERNAL_STANDARD
BNBrownPWM/PVG commandGAKI_PROJECT_CONVENTION_NOT_EXTERNAL_STANDARD
GYGraydiscrete output/relay commandGAKI_PROJECT_CONVENTION_NOT_EXTERNAL_STANDARD
OGOrangesafety-chain signalGAKI_PROJECT_CONVENTION_NOT_EXTERNAL_STANDARD
SLSlateshield/drain identificationGAKI_PROJECT_CONVENTION_NOT_EXTERNAL_STANDARD

这些颜色是GAKI A方案内部制造约定，不宣称是ISO/SAE强制色码；供应链或法规要求不同时应重新映射。

四、保险分支

保险ID支路家族候选最终A保护线冻结规则
F-ECU-RESMC050 RES ECUATO 287 / sealed ATO holderTBDW-RES-PWRsum controller + output/driver architecture, conductor ampacity, inrush and fault study
F-ECU-CHSMC024 CHS ECUATO 287 / sealed ATO holderTBDW-CHS-PWRcontroller load + output strategy + conductor study
F-SAFESC024 safety ECU / safety chainATO 287 / dedicated safety fuse holderTBDW-SAF-PWRsafety circuit analysis; branch faults must not defeat intended safety function
F-VB1Feed/conveyor anti-block valve blockATO 287 or MIDI if load justifiesTBDVB1 feedactual simultaneous coil current + conductor + duty
F-VB2Cutter/fan command/drive blockATO/MIDI depending on actual power architectureTBDVB2 feeddo not fuse by ECU command current if downstream electric drive has separate main power
F-VB3Hood/vent actuator blockATO 287TBDVB3 feedactuator stall/inrush + conductor study
F-VB4Cross conveyor/bin unload blockATO/MIDI depending on actuator typeTBDVB4 feedmotor/valve topology and jam/stall current
F-VB5Leveling valve blockATO 287TBDVB5 feedvalve current + safety/availability analysis
F-MAIN24 V main distributionMIDI 498 or MEGA 298TBDbattery-to-distribution cabletotal simultaneous load, cable ampacity, inrush and short-circuit study

五、BOM层级

层级总成说明数量冻结条件
1HARN-A-MAINA-scenario main machine harness1after chassis routing measurement
2HARN-H1-FRONTpickup/cutter front-zone branch1after front-module CAD
2HARN-H2-RESMC050 / fan / hood / pressure branch1after RES ECU placement
2HARN-H3-BINcross conveyor / bin / unload branch1after bin CAD
2HARN-H4-CHSMC024 / IMU / leveling branch1after chassis leveling layout
2HARN-H5-SAFESC024 / E-stop / guard / safety-enable branch1after safety requirements specification
2HARN-H6-HMIVCU/HMI/GNSS/service/CAN-B branch1after HMI/VCU hardware freeze
2PDB-A24 V power distribution / fuse block1after load and fuse study
2TERM-CAN-ACAN-A termination devices at backbone ends2 x 120 ohm nominalafter backbone endpoints freeze

六、制造质检

ID检查要求
QC01Verify each wire ID appears exactly once in manufacturing wire listREQUIRED
QC02Verify every used ECU cavity has correct contact gauge and sealREQUIRED
QC03Install sealing plug in every unused sealed cavity where requiredREQUIRED
QC04Use calibrated/approved crimp tooling for selected contact typeREQUIRED
QC05Perform sample crimp pull/tensile inspection and visual crimp inspectionREQUIRED
QC06Continuity test every wire end-to-end against netlistREQUIRED
QC07Insulation/short test between unrelated nets before ECU connectionREQUIRED
QC08Measure CAN backbone resistance powered down; target about 60 ohm after both 120 ohm terminators installedREQUIRED
QC09Verify Safety Enable cannot be bypassed by ordinary VCU/CAN commandREQUIRED
QC10Final harness length measured on real chassis; update all TBD length fields before production releaseREQUIRED

七、已核实制造细节

下载线束制造线表CSV →

下载连接器BOM CSV →

下载保险分支CSV →

下载BOM层级CSV →

下载制造质检CSV →