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Wire Harness Manufacturing Process(1)

Nov. 08, 2021

Wire Harness

This article is a brief introduction to the process of wire harness manufacturing. Please read on for more information.


I. Material

The original wire (usually coiled wire or barrel wire) is cut off and peeled according to the process requirements.

When the material is being fed, attention should be paid to the fact that the deviation is usually set to about +10, and no negative deviation should occur.

The downcomer should be debugged or repaired in time if there is instability in the case of the downcomer.

Downcomer generally has a fan for heat exhaust, if the discharge temperature is abnormally high, the machine should be turned off after inspection.

The tool of the lowering machine should be replaced in a timely manner after a long period of use and wear.

When the downcomer is used, it should be labeled, the label should be neat and clear, the content of the label includes the product type used, the length of the original line, both ends of the stripping length, and other information.

The finished material should be placed in different categories according to the location specified in the original wire area.


II. Pre-assembly

The first sub-assembly is prepared for crimping, which usually includes the following processes: wearing silicone tubes, wearing pull-back plugs and wearing waterproof plugs, and stripping of the two cores of the three-core wire.

Some of the larger terminals, if you need to go through the small silicone tube (such as diameter Φ6 silicone tube), you must first wear a good silicone tube at the sub-assembly, after crimping the terminal, not then cause the silicone tube will be too large terminal and pull but.

Back to pull the terminal, such as 1216 2190 and some plug connector, you must first wear the line into the plug connector, and then to be pressed terminals.

At this point, do sub-assembly process should be particularly careful, requiring the technician to plug and terminal very well understood.

Sub-assembly also pays special attention to is if the process requires the three-core wire cut or full winding with PVC, which must be in accordance with the wire harness process to operate.

Because some three-core wire insulation skin layer with conductive materials, if not cut or not to protect, it is easy to lead to leakage or touch fire, the consequences are very serious.


III. Crimping

Crimping is the use of crimping machines and other machinery and equipment to crimp the terminals and the original line together so that it can play a role in the connection of away.

The crimping process is completed, some terminals need to heat shrink. Heat shrink is a set of bare wires or terminals on the heat shrink tube on the air gun evenly baked until it is wrapped around the terminal or bare wire.

Heat shrink tube can be divided into single-layer and double two, single-layer heat shrink tube is mainly used for overlap, and double-layer is generally used for riveting points, their role is the same - to protect and prevent leakage.

In the baking process of the heat shrink tube, attention should be paid to the continuous turning of the baking, the line body and the surface of the heat shrink tube can not have the phenomenon of charring, if it is a double-layer heat shrink tube, the liquid flowing from the heat shrink tube should be fully and evenly wrapped around the line body.

Sometimes in the baking process will appear at the end of the bending deformation, which in principle is not allowed, but the actual operation is difficult to avoid, so as long as it does not affect the use, bending is not too serious are normal.


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