The wire harness processing flow generally includes the following steps:
Wire Cutting Process
Wire Receiving: Receiving wires that meet the specifications from the warehouse according to the production order, and verifying the wire model, specifications, quantity, etc.
Equipment Adjustment: Adjusting the parameters of the wire cutting machine, such as cutting length and cutting speed, according to the wire specifications and cutting length requirements.
Wire Cutting: Placing the wire into the wire cutting machine, starting the machine, and cutting to the set length. During the cutting process, carefully check the wire for defects such as damage or scratches.
Identification and Marking: Labeling the cut wires, using labels, color rings, etc., indicating the wire model, specifications, and intended use for subsequent processing and assembly.
Crimping Process
erminal Preparation: Selecting suitable terminals according to the wire specifications and connection requirements, and checking the terminals for defects such as deformation or burrs.
Adjusting the Crimping Equipment: Adjust the pressure, stroke, and other parameters of the crimping machine according to the type of terminal and wire to ensure crimping quality.
Inserting the Wire: Remove the outer sheath of the cut wire to expose a certain length of metal conductor, then insert the conductor into the corresponding position of the terminal.
Performing the Crimping: Start the crimping machine and perform the crimping operation on the terminal and wire. After crimping, check the firmness of the connection. This can be verified through methods such as tensile testing to ensure a reliable connection between the terminal and wire, with no loosening or detachment.
Pre-assembly Process
Preparing Pre-assembly Components: Based on the wiring harness design requirements, prepare the components to be pre-assembled, such as connectors, sheaths, relays, fuses, etc., and check their appearance and performance for good condition.
Installing Pre-assembly Components: Install the pre-assembly components into their corresponding positions according to the design drawings and process requirements. For example, install connectors to the ends of the wiring harness and relays to the designated brackets, ensuring secure installation and accurate positioning.
Pre-assembly Inspection: Inspect the pre-assembled wiring harness to check if the components are installed correctly, the connections are secure, and there are no missing or incorrectly installed components.
Assembly Process
Placing Cable Clips and Cable Ties: According to the wiring harness routing and fixing requirements, place cable clips and cable ties in the corresponding positions of the wiring harness to secure it and organize its shape.
Wire Harness Organization and Fixing: Organize the crimped and pre-assembled wires according to the design requirements, ensuring they are neat and orderly, avoiding wire crossing or tangling. Then use cable clips and cable ties to fix the wiring harness into the specified shape and size.
Install protective sleeves and corrugated tubing: To protect the wiring harness from external environmental influences, install protective sleeves or corrugated tubing on critical or wear-prone areas of the harness. For example, corrugated tubing is used on areas where the harness passes through body panels or rubs against other components, providing insulation, wear resistance, and protection.
Overall Inspection: Conduct a comprehensive inspection of the assembled wiring harness, checking if its overall shape and dimensions meet requirements, if wire connections are correct, if protective sleeves and corrugated tubing are properly installed, and if wire clips and cable ties are securely fastened.
Testing Process
Continuity Test: Use a continuity tester to test the continuity of each wire in the wiring harness, checking for open circuits, short circuits, or other problems.
Insulation Test: Use an insulation resistance tester to measure the insulation resistance of the wiring harness, ensuring its insulation performance meets requirements and preventing safety hazards such as leakage.
Withstand Voltage Test: Apply a certain high voltage to the wiring harness using a withstand voltage tester to test its electrical and insulation performance under high voltage conditions, checking for breakdowns, flashovers, or other phenomena.
Visual Inspection: Conduct a detailed inspection of the wire harness's appearance, checking for defects such as damage, scratches, and burrs on the surface. Inspect the insulation material for signs of aging or cracking, and ensure that connectors and terminals are securely installed and free from deformation.
Packaging Process
Cleaning the Wire Harness: Before packaging, use cleaning tools to clean the wire harness, removing dust, oil, and other impurities to ensure a clean appearance.
Selecting Packaging Materials: Choose appropriate packaging materials based on the wire harness's size, shape, and transportation requirements, such as plastic bags, cardboard boxes, or pallets. For some precision wire harnesses or those with special requirements, cushioning materials such as foam or sponge may be necessary.
Packaging: Place the cleaned wire harness into the packaging materials and proceed with the packaging process. Take care to protect the wire harness during packaging, avoiding damage from compression or impact. The packaging should clearly indicate the wire harness's model, specifications, quantity, and production date for identification and management.
