Manufacturing Process Of Wire Harnesses

Manufacturing Process Of Wire Harnesses

Summary

As a key component in modern industrial and electronic equipment, the complexity and accuracy of the manufacturing process directly affect the performance and reliability of the final product.

Manufacturing Process Of Wire Harnesses
As a key component in modern industrial and electronic equipment, the complexity and precision of the manufacturing process of the wire harness directly affect the performance and reliability of the final product. Whether it is automated equipment or complex aerospace equipment, the design and manufacture of wire harnesses need to follow a strict process flow. This article will explore the main process steps of wire harness manufacturing, covering technical points from basic to advanced.
Harness manufacturing process
Wire stripping process
Wire stripping is the first and most important step in wire harness manufacturing. The accuracy of wire stripping is directly related to the progress of the entire production. If there is an error in the stripping size, especially if the open wire size is too short or too long, it will lead to the subsequent trimming of all workstations, which is time-consuming and labor-intensive, and seriously affects production efficiency. Therefore, in the wire stripping process, it is necessary to strictly follow the requirements of the drawing to reasonably determine the wire open wire size and accurately strip the end size.
In actual operation, the following points should be noted in the wire stripping process:
Size control: Ensure that the stripping size is within the tolerance range, avoid stripping the conductor copper wire, and the cut stripping mouth needs to be flat.
Tool selection: Use a stripping tool suitable for the wire gauge to reduce damage to the wire insulation layer.
Inspection mechanism: implement self-inspection and mutual inspection system to timely discover and correct problems in the stripping process.
Crimping process
The crimping process is one of the core links in the manufacturing of wire harnesses, which determines the quality and mechanical strength of the electrical connection between the wire and the terminal. Determine the crimping parameters according to the terminal type required by the drawing, and prepare a detailed crimping work manual. If there are special requirements, they should be clearly marked in the process documents, and the operators should be trained.
In the crimping process, special attention should be paid to the following points:
Terminal selection: Select terminals that meet the design requirements to ensure that their electrical performance and mechanical strength meet the requirements.
Crimping tools: Use special crimping tools to ensure the consistency and reliability of the crimping process.
Tensile test: The tensile value of the terminal must be tested. If the tensile force does not meet the requirements, the crimping die must be readjusted to ensure that the connection between the terminal and the wire is firm and reliable.
Pre-assembly process
The pre-assembly process aims to improve the efficiency of the final assembly, which is particularly important in the manufacture of complex wiring harnesses. To this end, a detailed pre-assembly process operating manual must be prepared.
In the pre-assembly process, the following aspects need to be noted:
Path planning: Reasonably arrange the assembly path of the wires to avoid cross interference.
Component identification: Assign a unique number to each component and affix it to the material box for easy identification and management.
On-site optimization: Technical personnel should regularly summarize on-site and continuously optimize the pre-assembly process to ensure that it adapts to actual production needs.
Assembly process
The assembly process is the last step in harness manufacturing and the most complicated link. According to the assembly tray designed by the product development department, design appropriate assembly equipment and material box specifications and dimensions. All assembly kits and accessories should be clearly numbered and affixed to the material box to improve assembly efficiency.
In the assembly process, the following points should be noted:
Connector installation: Ensure that the connector is correctly installed in the specified position, check whether the locking mechanism of the connector is in place to prevent loosening or falling off.
Waterproof performance: For connectors that need to be waterproof, ensure that the sealing ring is correctly installed and conduct waterproof tests to ensure that its waterproof level meets the design requirements.
Electrical test: After assembly, a comprehensive electrical test is required, including continuity, insulation resistance and hi-pot test, to ensure that the electrical performance of the harness meets the design requirements.
Quality Control
Throughout the entire harness manufacturing process, quality control is carried out throughout. Effective quality control measures can ensure that the product quality of each link meets the standards, thereby improving overall production efficiency and product quality. Specific measures include:
Raw material inspection: Ensure that the wires, terminals and other materials used meet the design requirements.
Process monitoring: Real-time monitoring of the production process through online testing equipment to promptly detect and correct quality problems.
Finished product testing: Comprehensive functional testing of finished harnesses to ensure that their electrical and mechanical properties meet the standards.
Development Trends
With the advancement of technology, the manufacturing process of wire harnesses is also constantly developing. In the future, wire harness manufacturing will be more automated and intelligent to cope with increasingly complex market demands. For example, automated production lines can significantly improve production efficiency and reduce human errors; while intelligent management systems can help companies better manage production and quality.
With the rapid development of new energy vehicles, smart devices and other fields, wire harness manufacturing also needs to face new challenges such as high voltage, high speed and lightweight. This requires manufacturers to continuously develop new materials and technologies to meet market demand.

The wire harness manufacturing process is a complex process involving multiple links, from stripping to crimping, to pre-installation and final assembly, each step requires strict quality control and technical support. By continuously optimizing the process flow and adopting advanced technology and equipment, the high performance and high reliability of wire harness products can be ensured to meet the growing needs of different industries. With the continuous development of technology, the future wire harness manufacturing process will be more automated and intelligent, bringing more efficient and reliable solutions to all walks of life.