Introduction to the production process of automotive wire harnesses What are the testing standards for automotive wire harnesses?

With the continuous improvement of people's requirements for automobile safety, comfort, emission and economy, the application of electronic control units in automobiles is bound to be more and more, and the data exchange between electronic control units is becoming more and more complex. This requires that the design of wire harness must have high-quality data transmission capabilities, and it must save space and reduce the quality of the car itself. Then this article will briefly introduce the production process of automobile wire harness and what are the testing standards of automobile wire harness. Let's take a look!

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1. Introduction to the production process of automotive wire harness 1. Wire opening process The accuracy of the wire opening process is directly related to the entire production progress. Once an error occurs, especially if the wire opening size is too short, it will lead to rework of all stations, which will be time-consuming and laborious and affect production efficiency. Therefore, when preparing the wire opening process, it is necessary to reasonably determine the wire opening size and stripping size of the wire according to the requirements of the drawings. 2. Crimping process: Determine the crimping parameters according to the terminal types required in the drawings, make crimping operation instructions, indicate special requirements on the process documents and train operators. For example: some wires need to pass through the sheath before they can be crimped. They need to pre-install the wires first and then return from the pre-installation station before crimping. There are also puncture crimping that uses special crimping tools. This crimping The joining method has good electrical contact performance. 3. Pre-assembly process: First of all, pre-assembly process operation instructions must be prepared. In order to improve the efficiency of final assembly, complex wiring harnesses must be equipped with pre-assembly stations. Whether the pre-assembly process is reasonable or not directly affects the efficiency of total assembly and also reflects the technical level of a craftsman. 4. The final assembly process can be compiled according to the assembly platen designed by the product development department, design the specifications and dimensions of tooling equipment and material boxes, and paste the numbers of all assembly sheaths and accessories on the material boxes to improve assembly efficiency.

2. What are the testing standards for automotive wire harnesses? 1. The vehicle wiring harness should comply with: QC/T29106-2014 Technical conditions for automotive low-voltage wire harnesses (1) Specifies the standards for inspecting the size of the wire harness (2) Specifies the materials and components used in the wire harness. meet the performance requirements. (3) The connection method between the terminal and the wiring harness and the requirements to be met after connection are specified. (4) Specifies the requirements that the connection points between terminals and wiring harnesses should meet. (5) The sealing plug should not be damaged during crimping. There should be no visible gap between the wire and the sealing plug, and between the sealing plug and the sheath. (6) When wrapping the wire harness, it should be tight and uniform, and should not be loose. When the protective sleeve is used, there is no displacement and bending phenomenon affecting the wire harness. (7) The wires and parts in the wire harness should be assembled correctly, and there should be no misalignment, and the terminals should not come out of the sheath. (8) The line conduction rate in the wire harness is 100%, and there is no short circuit or wrong circuit phenomenon. (9) The wire harness needs to be tested for resistance to high, low temperature and humidity cyclic changes; Vibration resistance test; Salt spray resistance test; Industrial solvent resistance test, etc. 2. During the wire harness manufacturing process, the crimping between the wire harness and the terminals must meet: QC/T29009-1991 Common inspections and tests include: (1) Visual inspection: The surface of the joint should be clean and free of defects such as burrs and sharp corners when observed with naked eyes; The joints should be able to ensure that when mounted to wires or electrical appliances, there will be no breakage or cracks. (2) Moisture resistance test: It is carried out in an environment with a relative humidity of 90% ~ 95% and a temperature of 40f2 °C. After the sample lasts for 100 hours in the moisture-resistant box, take it out and dry it in the natural environment for 24 hours. Check that its contact joints must withstand the moisture resistance test without destroying its contact reliability. (3) The joint firmness test of the joints on the wires: Use a code or dynamometer to add a specified static tensile force on the joint under test according to the thickness of the wire harness, and observe it after 10 seconds. (4) Voltage drop test: The voltage drop measurement should be carried out after the moisture resistance test is completed. 3. Automotive battery wire harness connectors should meet: QCT29013-91 Automotive battery wire connector type, size and technical requirements. This standard mainly specifies the size specifications of the connectors connecting the battery wire harness to the positive and negative terminals of the battery. 4. QC/T417.1-2001 Automotive wire harness connectors This standard defines technical terms for automotive wire harness connectors, and specifies test methods and general performance requirements.

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