Automotive wiring harness process

With the continuous improvement of people’s requirements for comfort, economy, and safety, the types of electronic products in automobiles are also increasing, and the failure rate of more and more complex wiring harnesses for automobile wiring harnesses is correspondingly increased. This requires improving the reliability and durability of the wiring harness. The following is the QIDI automotive wiring harness process:
Opening process
Wire opening is the first station of wire harness production. The accuracy of the wire opening process is related to the entire production schedule. Once the opening wire size is too short or too long, it will cause all stations to rework, which is time-consuming and laborious and affects others. The progress of the product. Therefore, the opening process must be operated strictly in accordance with the drawings and tracked in real time.
Crimping process
The second process after opening the wire is crimping. The crimping parameters are determined according to the terminal type required by the drawing, and the crimping instructions are made. For special requirements, it is necessary to note on the process documents and train the operators. 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-installation station to crimp; and pierced crimping requires professional crimping tools. The connection method has good electrical contact performance.
Pre-assembled process
In order to improve the assembly efficiency, complex wiring harnesses must be equipped with pre-assembly stations. The rationality of the pre-assembly process directly affects the efficiency of the assembly and reflects the technical level of a craftsman. If the pre-installed part is missed or installed less or the wire path is unreasonable, it will increase the workload of the general assembler, so it is necessary to follow up in real time without interruption.
Final assembly process
According to the assembly platen designed by the product development department, design tooling equipment and material box specifications and paste all assembly sheaths and accessory numbers on the outside of the material box to improve assembly efficiency.
Automotive wiring harnesses are mainly based on terminal wires, and there are not many welding and forming, so it is mainly the leading terminal machine, with forming machines, testing machines, tensile machines, peeling machines, wire cutting machines, soldering machines, electronic scales, and punching machines as auxiliary.

The production process of automotive wiring harness:
1. Cut the wires strictly according to the drawings.
2. Crimp the terminals strictly according to the drawings.
3. Install the plug-ins strictly according to the drawings and divide them into small strands.
4. Assemble the small strands on a large tooling board, wrap them with tape, and install various protective parts such as corrugated pipes and protective brackets.
5. Detect whether each circuit is short-circuited, visual inspection and waterproof inspection, etc.

Post time: Sep-07-2020