The 4 major production steps of industrial wire harnesses

Automotive wiring harness is the main network of automotive circuits. Without wiring harness, automotive circuits would not exist. An automotive wire harness is a component in which a contact terminal (connector) made of copper is crimped to an electric wire and cable, an insulator or an external metal housing is molded on the outside, and a connection circuit is formed by bundling it with the wire harness. The following are several major production steps of industrial wiring harnesses:

1) The accuracy of wire stripping is directly related to the progress of the entire production. If there is an error, especially the short and long wire opening size, it will lead to the trimming of all stations, which is time-consuming and labor-intensive and affects production efficiency. Therefore, when stripping wires, it is necessary to reasonably determine the opening size of the wire according to the requirements of the drawings and cooperate with the terminals, and strip off the size of the ends. 2) Crimping process: Determine the crimping parameters according to the terminal types required in the drawings, prepare the crimping work instructions, and indicate them in the process documents if there are special requirements and train the operators. For example, some wires need to be crimped after being threaded into the sheath, and the wires need to be temporarily installed and returned from the temporary installation station for crimping; There is also a special crimping tool for puncture crimping, which has good electrical contact performance. In addition, the tensile value of the terminal must be tested, and if the tensile force does not meet the requirements, the crimping die needs to be readjusted. 3) Pre-assembly First, the operation instructions for the pre-assembly process must be made. In order to improve the efficiency of final assembly, pre-assembly stations must be set for complex wiring harnesses. The rationality of the pre-assembly process directly affects the final assembly efficiency and also reflects the technical level of technicians. The temporary installation part has less assembly and the assembly wire path is inappropriate, which will increase the workload of the final assembly personnel and reduce the speed of the assembly line. Therefore, technicians must often summarize on site. 4) The final assembly process is designed according to the assembly pallet designed by the product development department, and the specifications and dimensions of the assembly equipment and material boxes are designed. The numbers of all assembly sleeves and accessories are affixed to the material boxes, which can improve the assembly efficiency. Coordinate the assembly contents and requirements of each station, balance the overall assembly station, and avoid the situation that the workload is slightly large and the overall speed of the production line is reduced. To balance stations, technicians must familiarize themselves with each job and estimate man-hours on site, adjusting the assembly process at any time.

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