Automotive wiring harness processing common problem solutions, welcome to collect and use!

Solutions to common problems in automotive wiring harness processing: wiring harness processing process is generally: open wire (material cutting line) → crimping (branch crimping, terminal crimping) → assembly (pre-installation, winding, marking) → conduction test. Some of the problems and solutions in automotive wiring harness processing cutting line bad results: 1, peeling size is bad: resulting in the next process (crimping) can not be operated properly, which also leads to the failure of the finished product. 2, wire size is bad: wire size is too short, resulting in the failure of the finished product line. 3, the core damage, oxidation: poor crimping, false connections.

Defective product handling process: (size bad for example) 1. Operator: found that the size is too short, immediately find the reason for failure, communicate with the inspector to solve the problem, to prevent the emergence of bulk defective products, and the size of the short directly scrapped, shall not be mixed with the qualified products transferred to the next process; the size of the long reworking with the stripper pliers by the inspector to confirm whether it is qualified. 2. inspector: sampling found that the defective products, required to find out the reasons and immediately Rectification, and the evaluation of defective products to deal with, if there is a batch of defective products, should be immediately shut down to rectify, and reported to the immediate leadership. The result of poor crimping: 1, pull off the force is too small: wire core and terminal false connection or fall off. 2, generally poor crimping will lead to a large amount of waste of cost, and rework is difficult, very easy to scrap. 3, the cost of the crimping process: (pull off the force is too small: wire core and terminal false connection or fall off) Defective product handling process: (pull-off force is too small) 1. Operator: the pull force is too small should immediately stop crimping, and contact the mechanic on the crimping mold rest, reported to the inspector. 2. Inspector: the same type of crimped terminals (the last test passed to the discovery of defective), all according to the 2% sampling test, test found to have defective products will be judged that the batch of all failed to do a good job of marking and isolation, and notify the return to service. The results of poor assembly: 1, terminal exit: If the insertion of the terminal is not in accordance with the standard to perform, terminal exit is not easy to be found will be sent directly to the customer, terminal insertion is not in place will generally result in a false connection, resulting in burned cars. 2, terminal misalignment: ① terminal insertion of the wrong holes in the wiring harness if intercepted in the test bench will lead to the pre-assembly of employees and testers of the double reworking, which seriously affects the production efficiency. ② If the test area is mixed or missed test, the terminal insertion of the wrong hole will directly lead to the car line short circuit. Defective product handling process: (terminal inserted into the wrong hole) 1. Operator: ① found that the terminal inserted into the wrong should be immediately picked out with the appropriate tools and re-inserted into the sheath according to process standards. Try not to damage the parts during operation. ② will be the same type of all the sheath all self-check. 2. inspector: self-check is completed by the inspector of the type of sheath to confirm the full inspection, if again found defective, the implementation of the penalty regulations. Streamline bad results: 1, harness size is bad - resulting in the inability to load the car. 2, branching direction is not correct - short size when loading the car. 3, the secondary sub-assembly terminals are connected to the wrong - Rework or burn the car. Defective products processing process: (branching direction is incorrect) 1. operator: in the case of self-inspection or the inspector told the branching direction is incorrect, immediately improve, according to the correct branching direction of the winding, and will be non-conforming products marking, isolation, centralized and unified rework. 2. inspector: inspection works found in the defective products, defective products will be well marked, isolation, and immediately notify the workshop supervisor, the cause of the defective, to assist workshop Rectification. If there is a batch (30) quality problems, the full-time inspector has the right to stop the line to rectify, identify the causes, and report to the immediate supervisor.

Conductivity test process requirements: 1, the test failed harness marking, isolation (according to the model and the reason for failure to distinguish between the rework on the wire rack); 2, shall not be different types of harnesses on the same wire rack; 3, shall not be defective products hanging in the wire racks of the qualified products; 4, inspection of the qualified products in the specified time period to complete the packing; 5, no violent operation.

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