How to prevent moisture and corrosion of wire harness joints during roll on/roll off shipping protection

The roll on/roll off shipping environment is filled with salt spray, high humidity, and continuous bumps. Various sensors, car lights, and brake module harness connectors on heavy-duty truck chassis are prone to salt and water vapor infiltration, and metal terminals undergo oxidation and corrosion, resulting in signal interruption and circuit short circuit faults. Many vehicles appear to have normal electrical circuits at the beginning of arrival at the port, but after being delivered to overseas fleets for use for a period of time, faults occur in a concentrated manner. The root cause is the inadequate salt spray protection of the wiring harness joints during the shipping phase. Before loading, check the sealing status of the joint foundation, confirm that the sealing ring of the connector is intact and free of defects, and that the joint is fully fastened and locked in place to avoid water leakage caused by ship vibration. Do not use old sealing gaskets that have aged and hardened. Damaged gaskets will directly lose their waterproof ability. Apply specialized insulation and anti-corrosion grease to the exposed joints of the chassis, forming an isolation film on the surface of the metal terminals to prevent salt spray from adhering. When applying, control the amount to avoid excessive grease from contaminating dust. After completing the application, wrap the joint with moisture-proof self melting silicone tape, tighten it tightly without leaving any gaps, and focus on protecting the wheel end sensors, tail light joints, ABS wiring harness, and other low position areas of the chassis that are prone to splashing. The temperature difference between day and night on the deck of a roll on/roll off ship is large, and condensation is prone to occur inside the sealed joints. Before protection, it is necessary to ensure that the joints are completely dry and the surface is free of moisture. Directly wrapping them in a damp state will seal the moisture inside the joints, accelerating internal corrosion. Before driving onto the roll on/roll off ship, clean the surface dust and metal debris of the wiring harness joints. Impurities can damage the sealing and bonding effect. In terms of wiring harness layout, try to place the connectors facing downwards to reduce seawater droplets from directly entering the plug gaps. Use zip ties to secure the wiring harness to prevent navigation vibrations from pulling the plug and causing displacement of the sealing structure. It is prohibited to randomly unplug the wiring harness connectors that have already been inserted at the factory. Each insertion and removal will reduce the sealing performance of the sealing ring. Do not disassemble the connectors unless necessary. VCI rust proof bags or desiccants can be placed in the concentrated area of the chassis wiring harness to suppress salt spray corrosion. When dismantling and accepting vehicles at the port, priority should be given to dismantling the protective layer of key joints for inspection, observing whether there is white rust or green rust on the terminals, and promptly cleaning and treating any corrosion marks found. Many packaging personnel only focus on the protection of the frame paint surface, ignoring electrical small parts such as wire harness connectors. Salt spray corrosion has strong concealment, and the cost of replacing wire harnesses in the later stage is high, which will also delay customers' work. The core of roll on/roll off shipping wire harness connector protection is to do a good job of sealing and locking, dry isolation, physical wrapping, reducing salt spray and condensation from entering the terminals, avoiding circuit failures in advance, reducing overseas after-sales maintenance costs, and ensuring stable operation of the vehicle after delivery.