With the continuous improvement of the technical field, the harness structure and R&D technology are also constantly innovating. What do you know about the wire harness processing technology

1. Wire harness processing technology and inspection

1.1 General process

Raw material storage → automatic offline crimping → auxiliary operation → pressurized waterproof plug wire → inspection → drilling operation → packaging operation → pre assembly operation → assembly work → pipeline operation → 100% electrical inspection → full visual inspection → packaging operation → warehousing

1.2 Offline process

The offline process is to cut off the line according to the process file, stripping and binding process

Preparation of materials → adjustment of equipment → first article inspection (measuring line length is, head stripping) → batch production (100% self inspection during and final inspection) → wire sorting → waiting for turning

In the offline process, it is necessary to measure process parameters, such as line length, full and half peel length, and opening length

Wire harness processing

1.3 Crimping process

Crimping is the process of applying wires and terminals together

Prepare materials → adjust equipment → do the first piece → check the first piece (measure crimping height and crimping width with micrometer) → mass production (check 100% self inspection crimping quality in the middle and final) → to be rotated

During crimping, it is necessary to measure whether there is an R angle, whether the core wire's visible range and insulation are within the tolerance range, whether the core crimping part and the insulation material's pressing part are damaged or whether the crimping degree is crimped

1.4 Auxiliary process

Auxiliary procedures include wearing waterproof plugs, barbecue heat shrinkable tubes, sticking point dressings, binding wires, etc. Most auxiliary processes are manual. During the inspection process, it is necessary to fill in the production status record form of semi-finished products for auxiliary work, and inspect according to the process requirements

1.5 Pre assembly

Pre assembly is the process of assembling off-line or crimped semi-finished products into new semi-finished products, such as sheaths, pipe types, rubber parts

Prepare materials → one plug, two cans and three pullers → install self-locking

One insertion, two monitoring, and three pull back processes, according to the mandatory standard of Manual Training Specification for Wire Assembly, gently pull back the wire to complete self inspection

Wire harness processing

1.6 Final assembly

Final assembly is the process of combining semi-finished products, semi-finished products and other offline or crimped materials into a finished harness

1.7 Inspection process

The test process is carried out on the test bench, mainly including 100% electrical detection Image inspection, appearance inspection, installation accessories inspection and function inspection. Each finished product requires 100% electrical and visual inspection. The image inspection mainly detects the harness with fuse box to determine whether the fuse and relay plugs are correctly positioned. The function test bench is mainly used to detect the working state and relay of the relay in the harness. Check the torque of the bolt in the fuse box whether it works normally or not

1.8 Packaging process

Support and sealing → nylon binding tape → packaging and orderly placing → tape sealing → sticking certificate and serial number → adhesive packaging tape → storage

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