Key process methods for locomotive wiring harness manufacturing

Wiring Harness Manufacturing Process Overview: The HXN5 locomotive has approximately 30 wiring harnesses, of which the Z harness consists of approximately 1,000 wires of varying lengths and sizes, and this harness needs to be lifted by a crane. The wiring harness manufacturing process includes: preparation of wiring harness materials (including wires, terminals, connectors, tapes, wire number labels, insulating tapes, heat-shrink tubing, etc.). , the preparation of manufacturing tools (crimping machine, heat shrink machine, scissors, test equipment, etc.). , Stripping, wire numbering, terminal crimping, connector assembly, wire taping, harness testing, harness organization into the warehouse. Terminal Crimping: Terminals are used to connect wires and instrumentation. Wired power and signals flow into or out of the equipment through the terminals. Whether the quality of terminal crimping meets the requirements of the relevant standards is directly related to the normal operation of the instrumentation. The terminal consists of two key parts: the insertion area, the transition area and the crimping area. The assembled connector should be protected. Connectors are mostly used for locomotive signal and control lines. Dust and air moisture from the production site can intrude into the connectors, causing short circuits between adjacent lines and seriously affecting the normal signaling and control of the locomotive. Cover the whole connector with the protective sleeve that comes with the connector and tighten it to ensure the quality of the mechanism. The wiring harness is a neural network connecting different parts of the locomotive equipment, so the wiring harness is manufactured to be connected to the instruments and equipment on the locomotive. When wiring, bundles are made strictly in accordance with the routes specified by the terminal board. Only one binding tape can be used to cross-bundle at the crossover to effectively prevent the wiring harness from loosening. Strictly observe that small wires are tied to small sizes and large wires are tied to large sizes.

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