Automotive wire harness production process

One: stripping. The accuracy of stripping is directly related to the entire production schedule. Once an error occurs, especially if the opening size is short or long, it will lead to rework of all the stations, which will take time and effort to affect production efficiency. Therefore, when stripping the wire, it is necessary to determine the opening size of the wire and the size of the stripping head according to the requirements of the drawing in combination with the terminal to be hit.

Two: crimping process. Determine the crimping parameters according to the type of terminal required by the drawing, and make the crimping operation manual. For the special requirements, indicate and train the operator on the process documentation. For example, some wires need to pass through the sheath before they can be crimped. It needs to be pre-assembled and then returned from the pre-installed station and then crimped. Also, the puncture-type crimping uses a special crimping tool. The crimping method has good electrical contact properties. And be sure to test the tensile value of the terminal. If the tension is not up to the requirement, the crimping die needs to be re-adjusted.

Three: Pre-installed. Firstly, the pre-installation process operation manual should be compiled. In order to improve the assembly efficiency, the complex wiring harness must be equipped with a pre-installation station. The reasonableness of the pre-installation process directly affects the efficiency of the total assembly and reflects the technical level of a craftsman. If the pre-installed part of the assembly is too small or the assembled wire path is unreasonable, the workload of the total assembly personnel will be increased, and the speed of the assembly line will be slowed down. Therefore, the process personnel should often stay on site to summarize.

Four: assembly process. It can be programmed according to the assembly board designed by the product development department, design tooling equipment, material box size and attach the number of all assembly sheaths and accessories to the material box to improve assembly efficiency. Compile the assembly content and requirements of each station, balance the entire assembly station to prevent a situation where the workload is too large and pull down the entire assembly line speed. In order to balance the work station, the craftsman must adjust the assembly process at any time by familiarizing himself with each operation and measuring the working hours on site.

Wire harness production is mainly divided into two methods: end pressure (crimping) and forming. Nowhere is the best, it should be manufactured according to the requirements of the functional characteristics of the wire harness. And must fully inspect the product, test the continuity of the wire, resistance, voltage, etc., to ensure the yield of the product, to prevent the defective products from entering the market.