What are some of the common challenges in the wire harness manufacturing process?

The wire harness manufacturing industry is based on the combination of raw materials such as cables/connectors/plastic parts and adhesive tapes. The key technology is a series of processes such as peeling, cutting, terminal making, welding, crimping, thermal shrinkage, foaming and visual inspection. Automotive wiring harness designers will complete wiring and make drawings according to the CAN-BUS (Controller Area Network) bus technology for vehicle electrical distribution, including formal plans and 3D assembly diagrams, and then send them to the wiring harness manufacturers, who will make and confirm the drawings of tooling plates according to the drawings of customers. Then the factory can start production and manufacturing; there are several common difficulties in the production and manufacturing process of wiring harness inside the factory at this stage. The wrong insertion of 1、 means that the wire with terminals is inserted into the wrong connector hole, for example, it should be inserted into hole 1, because the worker mistakenly inserted into hole 2 next door, which will lead to ineffective function, which is a serious mistake. Generally, the corresponding parts of the tooling board will be posted with clear illustrations to inform the workers what color of the wire should be inserted into which hole, and the workers will not make mistakes by comparing the safe operation process. This kind of incorrect error is mainly due to the need to strengthen training and formulate protective countermeasures in the case of new employees and accelerated production, and the last step is the electrical measurement platform, so there is generally no need to worry too much. There are a number of processes within the factory that 2、 connector or fuse box damage, nodes must be set in advance to monitor and collect data to see at which step the error occurs, followed by analysis and action; typically damage is caused during incoming and shipping. 3、 the stage of pushing, locking and pulling the connector. This step must be done. First insert the hole and push it in place. At this time, it will make a clear sound. Then pull it out gently. If the wire does not go back, it means that it is inserted in place and fixed. If this step is not done well, it will cause the function to be invalid. Pay special attention to it.

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