1. Identify the Fastening Mechanism

Most overflow rings are secured by screws or a clamping mechanism. For modern designs, look for a small screw (often hidden) that clamps the ring to the sink body. If the ring is plastic, it might be held in place by a threaded plastic nut underneath the sink.

2. Remove the Drain Assembly (If Necessary)

Disconnect the drainpipe beneath the sink to access the overflow components.

Use a wrench or pliers to loosen the locking nut connecting the drain to the sink. This step may require removing the entire drain assembly to reach the overflow ring.

3. Loosen the Overflow Ring

For screw-fastened rings: Locate the screw (often on the underside of the sink) and use a screwdriver to remove it. If the screw is corroded, apply penetrating oil (e.g., WD-40) to loosen it.

For threaded rings: Use a pipe wrench or adjustable pliers to grip the ring and turn it counterclockwise. If it’s stuck, tap gently with a rubber mallet to break the seal.

4. Address Sealant or Adhesive

If the ring is sealed with plumber’s putty or silicone, carefully scrape away the residue with a utility knife or putty knife to avoid damaging the sink surface. 

5. Check for Hidden Clips or Gaskets

Some overflow rings have a rubber gasket or spring clip securing them. Remove the clip or pry out the gasket with a flathead screwdriver. 

6. Clean and Inspect

Once removed, clean the overflow hole and inspect the ring for damage. Replace any worn-out seals or gaskets to prevent future leaks.

Kohler toilets are known for their design and reliable performance, but like all plumbing components, some parts eventually wear out. One of the most common issues is a faulty flush valve. Whether you're dealing with a leak, a weak flush, or a constantly running toilet, replacing the flush valve can restore proper function. This guide will walk you through how to replace a flush valve on a Kohler toilet — whether it's the entire valve or just the inner canister — with tips on choosing the right parts based on your model and the types of toilet flushing systems.

1. Introduction

The flush valve controls how water exits the tank and enters the bowl. Over time, the valve may wear out, leading to water waste or inefficient flushing. This post focuses on Kohler toilet flush valves, particularly the 2-piece models, and will help you assess the issue, select the right part, and install it step by step.

2. Preparation Before Replacement

A. Diagnose the Issue

Before buying a new part, determine whether the entire flush valve is damaged or only the canister (also called the float or tower) needs replacement. If the tank structure is fine and only the center bucket is worn or cracked, you can save time and money by buying a flush valve repair kit.

B. Identify the Right Model

Kohler offers a wide range of valves, including the 3 inch toilet flush valve used in many of their modern models. Each flush valve dimension is typically matched to specific toilet models. Using the wrong size or type may lead to leaks or incompatibility. Always check the model number stamped inside the tank or refer to your toilet manual for an exact match. This is especially important for Kohler two piece toilet flush valve replacement tasks.

C. Tools You'll Need

Adjustable wrench, Screwdriver, Towel or sponge, Replacement flush valve or canister, Rubber gloves (optional)

D. Safety First

• Turn off the water supply

• Flush the toilet to empty the tank

• Disconnect the refill tube and chain from the flush lever

3. Installation Guide

Depending on your diagnosis, choose one of the following methods:

A. Full Flush Valve Replacement

When to choose: Cracked base, constant leaks, or worn-out sealing surfaces.

Removal Steps:

• Remove the tank lid and place it aside

• Disconnect the refill tube

• Unhook the chain from the flush lever

• Use an adjustable wrench to loosen the large plastic nut underneath the tank

• Lift the entire flush valve out and clean the tank bottom

Installation Steps:

• Insert the new flush valve into the tank hole

• Tighten the mounting nut from below

• Reattach the refill tube and flush chain

• Ensure everything is secure and aligned

B. Replacing Only the Canister (Bucket)

When to choose: The tank and base are fine, but the canister is leaking, warped, or sluggish.

Removal Steps:

• Remove the tank lid

• Disconnect the refill tube and flush chain

• Grip the canister’s crossbar and rotate counterclockwise to unlock it from the base

Installation Steps:

• Align the new canister’s notches with the base slots

• Rotate clockwise to lock in place

• Reattach the chain and refill tube

This is one of the easiest forms of flush valve repair kit usage and avoids tank removal entirely.

4. Testing and Adjustment

• Turn the water supply back on

• Let the tank fill and observe any leaks around the base

• Perform several flushes to ensure smooth operation

• Adjust chain length if the flush is too weak or the flapper doesn’t seal properly

5. Conclusion

Replacing a flush valve may sound technical, but with the right tools and guidance, it’s a straightforward task. Whether you're dealing with a Kohler two piece toilet flush valve replacement or simply swapping the flush valve repair kit components, proper installation ensures water efficiency and a reliable flush every time.

Always confirm your flush valve dimension and type before buying, as Kohler models vary widely among different types of toilet flushing systems.

The toilet is one of the most frequently used fixtures in any household, and the toilet fill valve is a key component that controls the water refilling process inside the tank. When problems such as slow filling or constant running occur, a faulty toilet fill valve is often the cause.

While it might seem like a job for a plumber, replacing a toilet fill valve is a fairly simple DIY task. It can save you time and money, and also gives you a better understanding of your home’s plumbing system.

In this guide, we'll walk you through the complete process of removing the old toilet fill valve, installing a new one, and adjusting water levels—so you can easily handle this home maintenance task yourself.

 Tools and Materials Needed

Before you begin, gather the following tools and materials to ensure a smooth installation:

a. Adjustable wrench or pliers – For loosening and tightening the locknut underneath the tank.

b.Bucket or towel – To catch any residual water that may leak during disassembly.

c. New toilet fill valve – Choose a compatible model, preferably a universal type with adjustable height. Make sure the universal toilet fill valve inlet matches your supply hose connector: 

• Europe & Africa: G3/8"
• Middle East: G3/8" or G1/2"
• Asia & South America: G1/2"
• Peru: G7/8" or 15/16-14NPSM
• North America: 15/16-14NPSM

Preparation

To avoid spills and ensure safety, follow these steps before removing the old valve:

Step 1: Turn off the water supply

Locate the shut-off valve near the toilet and turn it clockwise until it stops.

Step 2: Flush to empty the tank

Hold down the flush lever or button to drain as much water as possible from the tank.

Step 3: Place a bucket or towel under the tank inlet

This will catch any remaining water when you disconnect the supply hose.

Step 4: Disconnect the water supply hose

Use your hand or a wrench to loosen the hose from the base of the fill valve.

Removing the Old Toilet Fill Valve

Now you're ready to remove the existing valve:

Step 1: Loosen the locknut under the tank

Use a wrench to turn the plastic locknut counterclockwise.

Note: Some two-piece toilets have tight spaces that make it hard to reach the locknut. In such cases, you may need to detach the tank from the bowl for easier access.

Step 2: Pull out the old toilet fill valve

Lift the valve out from inside the tank. If it’s stuck, gently wiggle it back and forth to loosen it.

Step 3: Inspect and clean the inlet hole

Check for debris, hard water buildup, or damage. Clean the area with a cloth and inspect the rubber gasket—replace it if worn.

 Installing the New Fill Valve

Step 1: Adjust the new valve’s height based on the old one

Compare the old and new toilet fill valves, and adjust the body and float of the new valve to match the original height. Ensure the float doesn’t interfere with other tank components.

Step 2: Insert the valve into the tank

Slide the valve into the inlet hole with the rubber washer seated snugly inside the tank.

Step 3: Tighten the locknut from below

Secure the valve by tightening the locknut underneath the tank. Hand-tighten first, then use a wrench with light pressure.

Step 4: Reconnect the water supply hose

Attach the hose to the bottom of the new fill valve. Ensure a snug and leak-free fit.

Step 5: Connect the refill tube to the overflow pipe

Insert the refill tube into the flush valve’s overflow pipe and clip it in place. This small tube directs water into the bowl during refilling to maintain the water seal.

Testing and Adjustments

Step 1: Turn the water supply back on

Slowly reopen the shut-off valve and let the tank fill.

Step 2: Check for leaks

Inspect the base of the tank and the hose connection. If there are any drips, retighten the fittings.

Step 3: Adjust the water level

Use the height adjustment screw or float slider to fine-tune the fill level. The water should sit 1–2 cm below the top of the overflow tube.

Step 4: Test the flush

Flush the toilet 2–3 times to make sure everything works correctly and there are no slow fills or continuous running.

Tips and Common Issues

Replacing a toilet fill valve may seem technical, but with the right tools and a bit of patience, it’s a simple DIY task that anyone can accomplish. You’ve now learned how to identify issues, remove the old valve, install a new one, and make adjustments to ensure a perfect flush.

If you're looking for a reliable universal fill valve, consider one with adjustable height, a built-in filter, and quiet fill technology for a better experience.

Still have questions? Visit our Product page and select the Toilet Fill Valve category. Each product includes an installation video—simply choose the model that most closely matches your setup and follow along.

Take control of your home maintenance—one flush at a time!

1. Introduction

In modern homes and commercial spaces, dual flush toilets have become a mainstream choice for water conservation and environmental protection. Unlike traditional single-flush toilets, dual flush toilets offer two flushing modes—half flush and full flush—allowing users to select the appropriate water volume based on actual needs, effectively reducing water waste.

The design of dual flush toilets not only aligns with sustainability trends but also helps lower long-term water costs while providing more efficient flushing performance. Whether in homes, hotels, or public restrooms, dual flush toilets are widely favored for their water-saving, efficient, and durable features.

In this article, we will explore the water fittings of dual flush toilets and provide a detailed introduction to their key components, helping you better understand and choose the right products.

2. Water Fittings of a Dual Flush Toilet

The efficient operation of a dual flush toilet depends on the coordination of several core water fittings, each playing a crucial role in controlling water flow, optimizing flushing performance, and conserving water.

In general, the primary water fittings in a dual flush toilet include the toilet fill valve, toilet flush valve, and toilet flush button. Among these, the toilet flush valve and toilet flush button are key to the dual flush system, determining how the half and full flush functions are executed.

• Toilet Flush Valve: This component is responsible for releasing water from the tank to flush the bowl. Dual flush toilets typically use either a bucket-type dual flush valve or a cable-operated dual flush valve, ensuring precise water flow control and effective flushing.
• Toilet Fill Valve: This component controls the refilling of the toilet tank after flushing, maintaining a stable water level to ensure proper operation.
• Toilet Flush Button: The user operates the button to choose between a half or full flush. Depending on the installation type, toilet flush buttons can be top-mounted, side-mounted, or wall-mounted (for concealed cisterns).

A well-configured set of water fittings not only impacts flushing performance but also determines the toilet's lifespan and maintenance costs. In the following sections, we will provide a detailed overview of toilet flush valves and toilet flush buttons, helping you understand their functions and key selection criteria.

3. Introduction to Key Components

3.1 Toilet Flush Valve

• Function: The toilet flush valve is the core component of the toilet’s flushing system, controlling water release for both half and full flushes.
• Common Types: Bucket-type dual flush valve and cable-operated dual flush valve. These two designs differ in installation and operation but both effectively manage water volume and optimize flushing performance.
• Selection Criteria:
  • Size: Choose between a 2-inch or 3-inch toilet flush valve based on the toilet’s flush outlet size to ensure compatibility.
  • Overflow Pipe Height: Ensure it matches the toilet tank height to prevent overflow issues.
  • Overall Toilet Flush Valve Height: Should fit within the tank space for stable installation and effective flushing performance.

Selecting the right toilet flush valve can enhance the toilet’s flushing performance while reducing water consumption and maintenance costs. When installing or replacing a toilet flush valve, always ensure it matches the toilet’s specifications for the best results.

3.2 Toilet Flush Button

• Function: The toilet flush button is a critical user interface component that operates the toilet flush valve, allowing selection between half and full flush modes.
• Common Types: Based on installation type, toilet flush buttons can be top-mounted, side-mounted, or wall-mounted, suitable for different toilet designs.
• Selection Criteria:
  • Button Size: Common sizes include 38mm, 48mm, and 58mm. The correct size should match the tank hole diameter for proper installation.
  • Installation Type: Determine whether a top-mounted or side-mounted toilet flush button is required, depending on the toilet design.
  • Wall-Mounted Button Compatibility: For concealed cisterns, ensure the flush plate is compatible with the concealed tank, preventing installation and operational issues.

Choosing the right toilet flush button affects user experience and ensures precise flushing control. When selecting a toilet flush button, consider the toilet tank structure and personal preferences to achieve optimal convenience and performance.

4. Conclusion

Understanding the water fittings and key components of dual flush toilets reveals that selecting the right toilet flush valve and toilet flush button requires considering multiple factors, such as flush outlet size, overflow pipe height, installation type, and button size. These factors determine compatibility and performance, making the selection process complex for different markets.

For buyers uncertain about local toilet specifications or dealing with a variety of toilet types in their market, the most hassle-free solution is to choose a cable-operated dual flush valve with an adjustable overflow pipe. This type of toilet flush valve allows height adjustment to fit different tank designs, reducing installation issues. In this case, buyers only need to focus on the toilet flush valve size (2-inch or 3-inch) and toilet flush button size (38mm, 48mm, or 58mm), simplifying the selection process while ensuring a high success rate in compatibility.

Selecting the right water fittings not only enhances toilet performance and durability but also minimizes the risk of installation errors and additional costs. Jielin Plumbing offers a wide range of high-quality dual flush toilet accessories, catering to different market needs and helping buyers easily find the most suitable products.

1. Snow melting principle of heating cable

Electro thermal conversion

The alloy resistance wire inside the cable generates heat after being energized (the surface temperature is generally 40-50℃), and melts the snow through heat conduction, thereby preventing the formation of ice dams.

Self-regulating technology (some high-end models)

Due to the use of PTC materials, the lower the temperature, the lower the resistance, and the greater the heat output, thus achieving automatic power regulation, saving energy, and achieving optimal safety.

Zone control

The system uses temperature and humidity sensors or intelligent controllers and only starts in snowy weather or low temperatures to reduce energy consumption.

2. Installation steps and precautions

•  Preparation before installation

Land use planning

Cover eaves, gutters and other areas prone to snow and ice accumulation. It is recommended to use "inverted W" or "snake" wiring.

Cable selection

Power: generally 15~30W/m (appropriately adjusted according to cold climate, the recommended value in the north is ≥25W/m).

Type: It is best to use self-adjusting cables to prevent overheating and damage to roof materials.

• Installation

Surface cleaning

Remove debris from the roof and ensure that the cable is close to the roof.

Cable fixing

Fix with special clips or high-temperature resistant tape, maintaining a spacing of 30 to 50 cm.

Avoid drilling directly with a nail gun to avoid damaging the insulation layer.

Installation in the gutter

The cable is laid at the bottom of the ditch and can be covered with a metal sheath to prevent mechanical damage.

Electrical connection

Connect the cable to the GFCI (leakage protection) socket and seal the waterproof junction box.

It is recommended to use an independent circuit to avoid overload.

3. Safety tips

The cable spacing is ≥5cm and overlapping is prohibited. Avoid using flammable materials (such as asphalt membrane; use high-temperature resistant models).

Test the insulation resistance (≥1 MΩ) after installation.

Two suggestions and purchase points:

•  Purchase settings

Power: 20-30 W/m (higher value for very cold areas)

Voltage: 220V (home use) or 24V (safety low voltage)

Protection level: IP68 (waterproof and dustproof)

Warranty period: ≥10 years

• Maintenance and energy-saving tips

Regular inspection

Test the cables for normal operation before winter every year and clean up all dead leaves.

Smart control

Use a Wi-Fi thermostat (such as Honeywell T6) to start and stop remotely or trigger automatically.

Energy-saving tips

Use electricity only during the day (take advantage of freezing and thawing at night).

Choose the time of electricity use according to the electricity rate sharing area.

Looking back from the new starting point of 2025, we have experienced an extraordinary 2024 together. The global cable industry is undergoing structural changes: on the one hand, the AI ​​computing power revolution has spawned new opportunities, and the high-speed interconnection product line has maintained a compound growth rate of more than 30% for 18 consecutive months; on the other hand, the industry reshuffle has accelerated, and the profit margins of 78% of traditional cable categories have fallen below the 5% warning line. The high-speed interconnection supply chain is one of the product lines that currently maintains both profit and market growth. However, it is worth noting that the computing power arms race has entered a white-hot stage-the DeepSeeK algorithm revolution has compressed the computing power demand to 1/10 of ChatGPT, and NVIDIA has monopolized 83.7% of the global GPU market share with the H100/H200 series. This technological monopoly is triggering the reconstruction of the global supply chain. We have seen that Middle Eastern capital has set up a tens-billion-level GPU transit warehouse in South Korea through the Saudi sovereign fund, and India's Tata Group has jointly launched the "computing power corridor" plan with SoftBank. The domestic industrial landscape is also changing: H3C won a 15 billion high-speed order from Alibaba in a single month, Huawei's 8 billion AI server project was launched ahead of schedule, and the growth rate of the East China market was 42 percentage points higher than the traditional market in North China. This computing power revolution is reshaping our industrial landscape at an astonishing speed.

The most common application interfaces of high-speed interconnect cable harness components are SlimSAS, MICO, GEN Z, CXL, etc., all of which are dedicated to high-performance interconnect technology on the server side. Its mission is to enable processor-level bandwidth, from processor to system I/O to storage network, to traverse the entire data center, forming a unified neural network including server interconnection, server and storage interconnection, and storage network. These technologies are open standard high-bandwidth, high-speed network interconnection technologies. At present, their development speed is very fast, and more and more large manufacturers are joining or returning to its high-performance computer interconnection technology camp, so the demand for connected high-speed components is growing rapidly. In the existing resource library, there are 34 finished component factories. The difficulty of producing high-speed cable finished components is mainly to ensure the consistency and reliability of batch output. The difficulty lies in meeting the requirements of high transmission indicators, precise structural design and process control, high conductor requirements, material selection and cost balance, mass production and consistency, etc., to ensure stable performance during large-scale applications. 

According to the current market dynamics and industry analysis, the high-frequency and high-speed cable components used in AI servers have not yet seen a global overcapacity, but there is a structural contradiction, that is, insufficient supply of high-end products, and repeated investment in low-end technology may lead to local overcapacity risks. International giants occupy the high-end market and obtain the main profit space by relying on technology monopoly, while domestic enterprises compete fiercely in the mid- and low-end fields but have meager profits, and most of them are OEMs for the top four companies. In the future, with the acceleration of domestic substitution and technological breakthroughs, high-end production capacity is expected to be gradually released, but we need to be vigilant against the risk of local overcapacity caused by repeated investment in the low end. The following is a specific analysis:

Demand side: AI server growth drives a surge in demand for high-frequency and high-speed cables

Explosion of computing power demand

The rapid development of AI servers has put forward higher requirements for high-frequency and high-speed cable components. For example, the power consumption of a single cabinet of NVIDIA's AI server is close to 200kW, and may reach 1MW in the future, which puts higher requirements on the signal transmission rate, heat dissipation capacity and stability of the cable.

According to TrendForce's forecast, AI server shipments are expected to grow by 41.5% in 2024, and may still maintain a growth rate of 20%-35% by 2025, directly driving the growth of demand for high-frequency and high-speed cables.

Technology upgrade requirements

The interconnection standard of AI servers has evolved from PCIe 4.0 to PCIe 5.0/6.0, which requires higher transmission rates (such as high-frequency signals above 56GHz) and low-loss performance (low Dk/Df values) of cables. Traditional cables can no longer meet the requirements and need to rely on high-frequency high-speed cable assemblies.

Substitution and supplementary role

In short-distance connection scenarios (such as within a rack and between chips), high-frequency high-speed copper cables have become the mainstream choice for partial replacement of optical fibers due to their low cost and good compatibility. It is estimated that by 2027, the annual compound growth rate of high-speed copper cable shipments will reach 25%, and the market size will reach 20 million.

Supply side: insufficient high-end production capacity, low-end production capacity faces the risk of overcapacity

High-end products rely on imports and technical barriers

The core technologies of high-frequency high-speed cables (such as high-frequency signal integrity design and high-performance copper clad laminate materials) are still monopolized by international giants such as Amphenol and Tyco. Although domestic companies have made breakthroughs in the field of copper clad laminate resins (such as BMI and PPO), the large-scale production capacity of high-end cable assemblies has not yet been fully formed.

Low-end homogeneous competition

The traditional cable industry has a problem of low-end overcapacity. Some companies have tried to turn to the high-frequency and high-speed field, but due to insufficient technology, they have repeated low-level investments. In fact, high-speed lines are not as simple as you think. From structural design to production equipment, more attention needs to be paid to details, especially the requirements for equipment and process materials will be more stringent.

Market structure: structural imbalance and domestic substitution opportunities

Supply and demand mismatch

The high-end cable components in the global AI server market are still in short supply, especially for products such as 224Gbps SerDes and liquid-cooled compatible cables. International manufacturers have saturated orders and extended delivery cycles. However, due to technical and financial limitations, some domestic companies can only produce mid- and low-end products. The equipment investment after 6.0 is already at another level, resulting in local overcapacity.

Future trends: technology upgrades and industry integration

Technology iteration direction

High-frequency and high-speed cables will develop towards higher frequency bands and lower losses, and need to be compatible with liquid cooling systems. The popularity of cold plate liquid cooling will further promote the miniaturization and high-density design of cable components.

In the wiring harness industry, wire as the core component, its performance is directly related to the overall performance of the wiring harness system. From automobiles to electronic equipment, from industrial machinery to aerospace fields, wires bear the heavy responsibility of transmitting current and signals in various wiring harness application scenarios, just like nerves and blood vessels in the human body, ensuring smooth information and stable power transmission between various systems.

Key characteristics and engineering verification of wire conductors:

(1) The ultimate pursuit of electrical performance

In the automotive wiring harness laboratory built by Aichie, the conductor conductivity must be verified according to IEC 60228 standards:

High purity copper conductor: using 4N grade oxygen-free copper (purity ≥99.99%), which reduces the resistivity to 1.724×10⁻⁸Ω·m, reducing energy consumption by 15% compared with conventional copper. In the new energy vehicle 800V high voltage platform harness, this optimization can reduce the charging loss by 2.3%.

Intelligent insulation system: Crosslinked polyethylene (XLPE) is combined with ceramic filler through a three-layer co-extrusion process to increase the pressure level to 3000V/mm. The charging wiring harness developed by Aichie Zhizao for a German car company still maintains the insulation resistance > 500MΩ·km under the working condition of -40℃~150℃.

(2) Breakthroughs in the scenization of physical properties

In the field of industrial robot joint harness, Aichie Intelligent innovation application multi-dimensional testing:

Dynamic bending test: Based on the VDA 235-106 standard, 1 million ±180° bending tests are carried out on the multi-stranded copper wire to ensure that the breakage rate of the wire is < 0.1%.

Composite reinforced structure: The combination design of aramide fiber reinforced layer and silver-plated copper conductor makes the tensile strength of the wire reach 600MPa, which has been successfully applied to the spacecraft solar panel drive wire harness.

(3) Strict verification of environmental adaptability

For the tropical automotive market, Aichie has developed special protective wires:

Salt spray test: 2000 hours of test under ASTM B117 standard, tinned copper conductor corrosion area rate < 5%.

Oil resistant solution: Using polyamide (PA) insulation layer, the volume expansion rate is < 3% after 1000 hours of oil immersion at 120℃, has been used in batches for heavy truck engine wiring harness.

Cable selection: Select the cable type based on the application scenario

Automotive industry: In the engine compartment, due to high temperature, vibration, oil and other complex environment, high temperature, oil and vibration resistant wires are often used, such as German standard FLRY-A and other models of wires; The door wiring harness needs to be bent due to frequent switching, and more flexible AVSS (thin insulated) wires are used. For sensors that transmit weak signals, such as knock sensors and crankshaft position sensors, electromagnetic shielding wires are required to prevent electromagnetic interference.

In the field of electronic equipment: In the miniaturized and high-performance electronic equipment such as mobile phones and tablet computers, the wires need to have the characteristics of small size, high precision and good flexibility. For example, FFC (flexible flat cable) terminal line can be arbitrarily selected the number and spacing of wires, greatly reducing the volume of electronic products, often used for motherboard and display, camera and other components to connect to achieve signal and power transmission.

Industrial equipment: industrial automation production line environment is complex, large vibration, strong electromagnetic interference. Wires used to connect industrial robots, CNC machine tools and other equipment, in addition to good electrical performance, but also need to have a high anti-interference ability and resistance to harsh environment, such as the use of double-layer shielded wires to resist electromagnetic interference, the use of wear-resistant, corrosion-resistant materials to deal with harsh industrial environments.

Aerospace: Aerospace wire harness wire requirements are very strict, need lightweight, high strength, high temperature resistance, radiation resistance. Wires are mostly made of special alloy materials and advanced manufacturing processes, such as silver-plated copper wires, which can ensure good electrical conductivity and reduce weight; The insulation material is made of polyimide and other high-performance materials to adapt to the extreme space environment and complex working conditions at high altitude.

The development trend of wire

(1) Research and development and application of high-performance materials

With the continuous improvement of wire performance requirements in various industries, the development of new high-performance materials has become a trend. In terms of conductor materials, in addition to optimizing the performance of copper and aluminum, the exploration of new conductive materials, such as carbon nanotube composite materials, is expected to achieve higher conductivity and better comprehensive performance. In the field of insulation materials, the research and development of materials with higher temperature resistance, radiation resistance and anti-aging properties, such as new ceramic based insulation materials, high-performance fluorine plastics, etc., to meet the needs of high-end fields such as aerospace and new energy vehicles.

(2) Miniaturization and lightweight design

In order to adapt to the development trend of miniaturization of electronic products and lightweight of automobiles, wires are developing in a thinner and lighter direction. On the one hand, by improving the manufacturing process, the diameter of the wire and the thickness of the insulation layer are reduced under the premise of ensuring the electrical and physical properties. On the other hand, the use of lightweight materials to replace the traditional heavier wire materials, such as in aerospace wire harnesses, the use of lightweight alloy wires and low-density insulation materials, while reducing the weight of the wire harness, without affecting its performance, improve the overall competitiveness of the product.

(3) Intelligent and multi-function integration

In the future, wires will not only be limited to the transmission of current and signal functions, and intelligent and multifunctional integration will become the development direction. For example, the research and development of a wire with self-monitoring function can monitor the temperature, current and other parameters of the wire in real time, once there is an abnormal early warning, improve system safety and reliability; The wire is integrated with sensors, communication modules, etc., to realize the integration of data acquisition, transmission and processing, and to provide support for the development of smart devices and smart grids.

Wire as the key basis of the wire harness industry, its performance, selection and development are closely related to the technical progress and product upgrades in various application fields. Continuously improving wire performance, optimizing selection criteria, and keeping up with development trends are the core driving forces for the continuous innovation and development of the wire harness industry.

In the wave of electrification and intelligence, Aichie will continue to deepen the core technology of wire research, to provide global customers with more reliable, more cost-effective wire harness solutions.

With the rapid development of automotive, electronics, communications and other fields, as an integral part of connecting internal components, the demand for wire harnesses continues to grow, which is not only a key component to ensure the normal operation of product functions, but also an important guarantee for product quality, safety and reliability. However, in the face of increasingly complex market demand and requirements for environmentally friendly production methods, wire harness processing industry is facing new challenges, how to improve production efficiency, reduce costs, ensure product quality and reduce environmental pollution at the same time, has become a major wire harness processing enterprises to solve the problem, automation and intelligence is undoubtedly the two core trends.

The "automation" engine continues to power, and the wiring harness equipment innovation runs out of "acceleration"

Generally speaking, wiring harness manufacturing process includes wiring, crimping, preassembly, assembly four links, of which wiring, crimping belongs to the former process, the high level of automation, while preassembly and assembly and other post-process tradition is mostly rely on manual manual assembly. Therefore, for a long time, wire harness processing has been regarded as a labor-intensive industry, especially in the post-assembly process such as pre-assembly and final assembly, the level of automation is low, the cost is high and the quality is difficult to guarantee. In order to solve these problems, more and more enterprises have begun to develop advanced automatic processing equipment, such as automatic stripping machine, terminal crimping machine, etc., which not only greatly improves production efficiency, but also significantly improves product quality and consistency.

Aichie Wire Harness Factory has significantly improved production efficiency and product quality through the introduction of leading automated production equipment, including advanced equipment such as precision terminal crimping machine and intelligent wire stripping machine. Aichie's intelligent manufacturing system achieves three core advantages:

1. Excellent quality: Using high-precision automation equipment to ensure product consistency of more than 99.9%

2. Cost advantage: Automated production reduces labor costs by 40%, providing customers with more competitive prices

3. Efficient delivery: 60% increase in production efficiency to ensure on-time delivery of orders

Through continuous technological upgrading and intelligent transformation, Aichie Wire Harness Factory is meeting the increasing needs of customers with better products and services.

Revelation:

The intelligence of medium-sized wiring harness factory is not a simple equipment competition, but needs to grasp three key dimensions:

Precise positioning: Deep cultivation of high value areas such as high pressure/special wiring harness

Progressive investment: Phased implementation of digital transformation (recommended ROI cycle control within 3 years)

Deep binding: Build technology symbiosis with customers through joint development

In this industrial revolution led by automation and intelligence, Aichie wire harness factory has proved in practice that wire harness processing is no longer a simple "wire connection", but needs to integrate material science, precision manufacturing, data intelligence complex technology system. When traditional enterprises are still anxious about labor costs, pioneers have established an insurmountable moat through technological innovation - this may be the best period for manufacturing in China to transition to intelligent manufacturing in China.

As the market explosiveness of new energy vehicles continues to increase, the market size of automotive connectors continues to expand. According to Bishop & Associates (a global connector market research organization), the global automotive connector market size will reach US$19.452 billion in 2025, of which China's automotive connector market will account for 23% of the total, with a size of approximately US$4.468 billion. China is the world's largest automobile producer and also a leading country in the research and development and output of new energy vehicles. In the next few years, the size of China's on-board connector market is expected to exceed the forecast of Bishop & Associates.

High-voltage connector technology: high standards

The so-called "high-voltage connector" is a connector that serves the high-voltage system in the car. Traditional fuel vehicles mainly rely on engines and fuel to meet the requirements of the car for mechanical kinetic energy, and do not have too many requirements for voltage; while electric vehicles use electricity as energy, and use power batteries, drive motors, and drive motor controllers to complete the kinetic energy supply of the car, which puts forward higher standards for the voltage and current carrying capacity of related components.

High-voltage connectors and electric vehicles are interdependent. In 2009, my country issued the "Automotive Industry Adjustment and Revitalization Plan" and launched the "Ten Cities, Thousand Vehicles" subsidy plan to promote new energy vehicles. Since then, my country's high-voltage connectors have continued to move forward with the pace of new energy vehicles, and have developed to the fourth generation by 2022.

Xu Ping'an, chief technology officer of Basba, told us that the newly added "secondary unlocking" function of the third-generation product can protect the core electrical parts of the product and ensure the safety of users; the fourth-generation product is smaller in size, has a higher current density, and a controllable temperature rise, providing better safety and reliability for high-power charging and discharging. Basba New Energy Technology Co., Ltd. is a company focusing on high-voltage connection system solutions for electric vehicles, with 12 years of experience in the research and development of vehicle-mounted connectors. High-voltage vehicle-mounted connectors are mainly used in lithium batteries, motors, electronic controls, DC/DC converters, OBCs, PDUs and other systems, and work together with high-voltage wiring harnesses to transfer battery kinetic energy to various components with the help of high-voltage and high-current lines. Different system components and differences in the cross-sectional area of ​​wires have different electrical performance requirements for vehicle-mounted connectors. Generally speaking, the rated voltage values ​​of high-voltage connectors range from 60v to 1500v, and the rated current values ​​range from 20A to 300A. In addition, vehicle-mounted connectors also have high requirements for the mechanical and environmental performance of products. High-quality high-voltage connector products must pass various mechanical performance tests, environmental tests, and electrical performance tests, such as terminal retention, connector plug-in and pull-out force, drop test, 960H neutral salt spray test, 1008H aging test under 125℃ environment, -40℃~125℃ hot and cold shock, etc. As electric vehicles continue to move towards fast charging and super charging, various new energy vehicle companies are constantly improving the vehicle voltage platform. 2022 will be the first year for the upgrade from 400v to 800v high-voltage platform. The new challenges brought to high-voltage connectors are still concentrated on the electrical level. Can the rated voltage and rated current be further improved? And how to deal with the high temperature hazards caused by high-power current? The fifth-generation high-voltage connector is very likely to combine with liquid cooling technology to meet electrical and temperature requirements.

Supply and demand side of high-voltage connectors: large market

New energy vehicles can be divided into two categories: new energy passenger vehicles and new energy commercial vehicles according to their use.

According to the data of China Automobile Association, from January to September this year, the cumulative sales of new energy passenger vehicles reached 4.363 million units, a year-on-year increase of 111.5%; the cumulative sales of new energy commercial vehicles reached 204,000 units, a year-on-year increase of 80.1%. New energy passenger vehicles and commercial vehicles are driving the continuous expansion of the market for high-voltage connectors. In the field of low-voltage connectors, due to the difference in the time of automobile manufacturing, the technical patents have long been in the hands of foreign car companies, and the gap between the domestic and foreign low-voltage connector markets is significant. If the short board of my country's on-board connectors is the low-voltage connector, then the long board is at the end of the high-voltage connector. This is due to the rapid development of my country's new energy vehicles. Domestic car companies are keeping pace with foreign car companies, and even beautifully surpassing and leading. In the field of new energy commercial vehicles, high-voltage connectors have achieved a localization rate of nearly 100%, and have also surpassed foreign countries in terms of technology. my country's high-voltage connectors used in new energy commercial vehicles use integrated panels and have developed for many generations, while similar foreign products still retain the traditional lock body structure. At the same time, my country's new energy passenger car high-voltage connectors are also constantly increasing the domestic penetration rate. At present, the major enterprises in my country that have deployed high-voltage connectors for passenger cars include Rekoda, AVIC Optronics, Basba, Yonggui Electric, and Sunco Intelligent. Basba revealed that the localization rate of high-voltage connectors for passenger cars has exceeded 60%. In addition to the localization rate, high-voltage connectors are also far more valuable than low-voltage connectors. Since the battery pack capacity of new energy commercial vehicles is several times that of passenger car battery packs, the value of commercial vehicle high-voltage connectors is higher than that of passenger car high-voltage connectors.

The future of high-voltage connectors: modularization

The technical orientation of supercharging and fast charging for new energy vehicles also affects the on-board connectors. As the battery capacity increases, the body becomes heavier and heavier, and the connectors and wiring harnesses are used more and more. Therefore, the modularization of components becomes more and more important.

The modularization of high-voltage connectors has many benefits. "Multifunctional integration and modularization can better meet the safety requirements of the whole vehicle. Lightweight, easy installation, lower cost, improved aesthetics, etc., these are the benefits of modularization and integration." Regarding the development trend of high-voltage connectors, Xu Ping'an, chief technology officer of Basba, also emphasized modularization and lightweight. In addition, the electromagnetic compatibility and volume current ratio capabilities of my country's high-voltage connectors and wiring harness assemblies also need to be continuously improved. The research and development certification of automotive-grade connectors is different from that of other types of connectors. For safety, reliability, and durability considerations, the total cycle of product self-certification plus customer certification is longer. High-voltage connectors and new energy vehicles are a "community of destiny". Riding the wind of new energy vehicles, the high-voltage connector market is soaring.

With the rapid development of the global new energy vehicle industry, high-voltage wiring harnesses, as the "major arteries" for energy transmission in electric vehicles, their processing quality directly affects the safety and reliability of the entire vehicle. Compared with the low-voltage wiring harnesses of traditional fuel vehicles, the high-voltage wiring harnesses of new energy vehicles need to withstand working voltages of 300V to 800V and large currents of over 200A, which puts forward higher requirements for material selection, production processes and quality control.

As a professional automotive wiring harness manufacturer, Aichie Tach Manufacturing has supply high-voltage cable assemblies solutions for over 30 new energy wiring harness customers. Its products have passed international certifications such as IATF16949/UL/CE/TUV.

I. Selection of Core Materials for High-Voltage Wiring Harnesses

Conductor material: Multi-strand twisted copper wire (cross-sectional area 16mm²-150mm²) is adopted, with tin plating to enhance oxidation resistance. Silver-plated copper wire is used in special scenarios to reduce contact resistance

2. Insulating materials: Cross-linked polyethylene (XLPE), silicone rubber or polytetrafluoroethylene (PTFE), with a temperature resistance grade of 150℃-200℃

3. Shielding layer: Double-layer shielding structure (aluminum foil + braided copper mesh), with a shielding coverage rate of ≥85%, effectively suppressing electromagnetic interference

4. Sheath material: Flame-retardant TPE or TPU material, which has passed UL94 V-0 flame-retardant certification, and the wear resistance coefficient needs to meet the industry standard

II. Wiring harness design Verification Stage

1. 3D wiring simulation: Utilize CATIA software to simulate the layout of the entire vehicle wiring harness, avoiding mechanical interference and electrical performance calculation in heat source areas: Accurately calculate voltage drop (≤3%), temperature rise (ΔT≤40℃), and current-carrying capacity margin

2. EMC simulation test: Predict the electromagnetic radiation value through CST software and optimize the shielding layer structure

3. Sample environmental testing: Conduct a 2000-hour salt spray test, 3,000 plug-and-pull tests, and a temperature shock test ranging from -40 ° C to 150 ° C

III. Core Processing Technology Flow

(1) Cable pretreatment

1. Automatic wire cutting: A servo-driven wire cutting machine is adopted, with the precision controlled within ±1mm. The cut surface should be smooth and free of burrs

2. Laser marking: Use ultraviolet laser to engrave line numbers, specifications and other information on the surface of the sheath, with a depth of 0.15-0.3mm

3. Terminal crimping: Completed by a fully automatic crimping machine, with a crimping height tolerance of ±0.02mm. The metallographic analysis of the profile must meet the VW60330 standard

4. Shielding treatment: Double-layer shielding layers are treated separately, with 360° aluminum foil covering and copper mesh braided density ≥90%

(II) Component Assembly

Injection molding: A vertical injection molding machine is used, with the mold temperature controlled at 80±5℃. The holding time is set according to the thickness of the material

2. Waterproof treatment: A double sealing structure (rubber gasket + potting compound) is adopted, with a protection level reaching IP67/ IP6K-9K

3. Assembly of high-voltage connectors: The pneumatic crimping equipment applies a torque of 50-80N·m, and the contact resistance is less than 0.5mΩ

4. Wire harness binding: High-temperature resistant cable ties are fixed at intervals of 150-200mm, with a bending radius of no less than 5 times the wire diameter

(3) Process Inspection

1. Online high-voltage testing: 2000V DC withstand voltage test (leakage current < 1mA/min), 1500V insulation resistance test

2. Conduction test: The micro-resistance tester detects the circuit impedance, with a deviation value of no more than 5%

3. Mechanical property test: Maintain a tensile force of 35kg for 1 minute, and the terminal displacement should be less than 0.2mm

4. Air tightness test: 3kPa air pressure test, leakage < 5mL/min

IV. Breakthroughs in Key Technologies of the industry

Lightweight technology: Aluminum wires are used to replace copper wires, reducing weight by 30% while maintaining electrical conductivity

2. Modular design: Develop integrated high-voltage distribution boxes to reduce connection nodes by more than 50%

3. Automated production: The introduction of six-axis robots enables automatic wiring, increasing efficiency by 40%

4. Intelligent detection System: By applying machine vision and AI algorithms, the defect detection rate has been increased to 99.8%

V. Key Points of Quality Control

1. Cleanliness management: The production environment maintains the ISO 14644-1 Class 8 cleanliness standard

2. Traceability System: Establish an MES production traceability system, with key parameters retained for at least 10 years

3. Process capability index: Critical dimensions CPK≥1.67, electrical characteristics CPK≥1.33

4. Aging test: 100% of the products undergo a 72-hour live aging test

VI. Industry Development Trends

Voltage platform upgrade: Develop new materials capable of withstanding 1000V for 800V high-voltage systems

2. Integrated development: Integrate fuses and current sensors into the wiring harness assembly

3. Application of liquid cooling technology: Development of integrated high-voltage wiring harnesses with cooling pipelines

4. Sustainable manufacturing: Establish a copper material recycling system, and increase the material utilization rate to 98%

The processing of high-voltage wiring harnesses for new energy vehicles is a deep integration of precision manufacturing and intelligent technology. From conductor selection to assembly testing, each link needs to strictly follow standards and specifications such as IEC 62196 and GB/T 18487. With the increase of voltage platforms and the development of intelligent driving, high-voltage wiring harnesses will evolve towards high integration and intelligence in the future. Aichie will continue to improve its process technology and establish a full life cycle quality management system to provide reliable guarantees for the safe operation of new energy vehicles.