Drawing of Harness Tooling Board

In order to meet the electrical performance of the vehicle, automotive Wiring Harness designed and output the electrical schematic diagram of the vehicle according to the electrical architecture of the vehicle after preliminary investigation and analysis. In order to meet the wire harness layout of the whole vehicle, the three-dimensional layout trend of the wiring loom in the whole vehicle is determined according to the structural position and pipeline layout of electrical devices, the division and integration of wiring harness modules and the protection requirements, and the 2D topology of the wiring harness is established. According to the schematic diagram of the harness and the 2D topology of the harness; So as to form a modularized two-dimensional wiring harness drawing.

The Wire Harness is processed with reference to two-dimensional drawings, but in the actual processing process, due to the different complexity of the wire harness and different customer needs, the processing mode is different. For complex wire harnesses and wire harnesses with high requirements from customers, it is necessary to expand and lay out the dimensions in the drawings in a scale of 1:1 according to the two-dimensional wire harness drawings, so as to form a wiring harness fixture board drawing, which is convenient for wire harness processing. The following are some of my experiences in drawing the wiring harness fixture board drawing in the course of my work, which are described and shared after finishing, hoping to discuss the progress together.

The wiring harness tooling plate diagram is the most direct guiding technical document for front-line employees in the assembly process of wiring harness products. The intuition and popularity of the tooling plate diagram directly affect the processing efficiency of assembly employees. Commonly used auxiliary materials for binding outside the wire harness are: bellows, adhesive tape, textile sleeve, Desha cuff adhesive tape, braided sleeve, PVC sleeve, PVC cloth, nylon braided sleeve and zipper PVC sleeve. The common ways of binding the wire harness are: a, the outer half-overlapping wrapping of the wire harness (tape tight wrapping), local wrapping (tape point wrapping) and coarse wrapping (tape flower wrapping). B. Bundling methods of external auxiliary materials of wire harness: semi-overlapping wrapping (tape tightly wrapped), local wrapping (tape point wrapped) and coarse wrapping (tape flower wrapped). C, the types of tapes used in different parts are also different, including: duct tape, flannel tape, PVC tape, sponge tape, grid tape, etc. In view of the above-mentioned auxiliary materials and wrapping methods, it is particularly important to select the graphic representation of auxiliary materials assembly methods of different wire harness branches when the drawing of wiring harness tooling board is initially set.

In the process of product processing, in order to improve the productivity and ensure the output efficiency of products, the wiring harness fixture board is often laid out in the form of rotating assembly line, so the version of the fixture board is limited. Considering the matching degree of ergonomics, the width of the tooling plate is usually about 90 cm, and the processing mode of the rotating assembly line also needs to make certain restrictions on the length of the tooling plate, which usually has two sizes of 4 meters and 6 meters. The demand of products is different, and the three-dimensional branch direction and specific branch point wrapping method in the tooling board drawing are different. The common binding methods of branch points are: Y-type /T-type/cross-type/claw-type. In general, the branch layout is carried out with reference to the 2D wiring harness drawings given by the main engine factory without the 3D trend diagram, and if there is a 3D trend diagram, it shall be strictly followed. The 1: 1 layout of the wiring harness fixture board is carried out in strict accordance with the design requirements. The layout process is mainly based on drawings, supplemented by the convenience of processing. If you encounter special connectors and special branches, the branch point cannot be placed at the inflection point of the layout of the tooling board. In the layout process, the maximum size of the tooling board is limited, so it is inevitable that the wiring harness with a long total length will be bent in the layout process of the wiring harness tooling board diagram. In order to reduce the loss of wires in the line hanging process, the angle of the inflection point is recommended to be not less than 90 degrees. At the same time, in order to prevent the conductor from falling down due to gravity without fixture support in the middle, when the length of the branch or trunk is greater than 1 meter, it is suggested to increase fixture points in the middle as support.

The fixture plate drawing of fixture harness is a special vehicle, and there are many auxiliary materials (buckles, pipe clamps, etc.) in the wiring harness processing process, and the drawings have precise size, position and direction requirements. In order to facilitate the process identification of front-line employees, the fixture plate drawing is considered in the fixture plate drawing design, that is, a special positioning fixture module is developed for auxiliary materials and connectors that need special distinction. In the early stage of fixture development, the pick-up points of fixture columns are standardized according to the pick-up points required in the drawings (in two cases), so as to avoid a lot of measurement and modification of the wiring harness fixture plate drawing after the fixture arrives. The first type: for the Connector with no restriction on the outlet direction of the connector, the end face of the fixture cavity is where the center line of the fixture column is located if the sampling point is on the butt face of the connector, and the center line of the column is located on the end face of the inlet end if the sampling point is on the inlet end of the connector. The second schematic diagram of the inch point on the distribution board diagram: for the connector with limited outlet direction of the connector, if the inch point is far away from the inlet end of the connector, the position of the center point of the column is on the far away surface of the inlet end of the connector; If it is at the inlet end of the connector, the position of the center point of the column is on the end face of the inlet end. In the process of processing the schematic diagram with inch points on the distribution board diagram, due to the difference in the slotting depth or the matching degree with the physical size of the corrugated pipe bifurcated pipe clamp and connector fixture, the pipe clamp will come off, which is not convenient for wiring harness processing, and may also lead to the change of wiring harness size, so it is necessary to add a limit pick on the fixture. After a bifurcated pipe clamp is installed, it is fixed on the fixture with a limit pick, which can effectively reduce the size variation, facilitate processing and improve the quality of product processing.

Multi-functional fixture selection When drawing the fixture harness fixture board diagram, there are many local auxiliary materials (buckles, pipe clamps, etc.) in the drawing, resulting in dense fixture in this part, which is very inconvenient for operators in the wiring harness finishing process. Considering the convenience of the wiring harness processing process, in the location with dense fixture, telescopic clamping can reduce the fixture density in a certain area and reserve space for operators. There is a big difference between the required aperture on the on-line harness tooling plate of the telescopic nail clamping fixture and that of the common nail clamping fixture. At the initial stage of drawing the tooling plate, the required drilling size of various nails is indicated, and at the same time, the type of drill bit used is indicated to improve the convenience of the processing process.

Summarize through the above discussion, combined with the actual processing practice. Harness processing harness tooling plate directly affects the process quality of product processing, and the completeness and accuracy of tooling plate drawing, as well as the intuition and convenience of use, all play a vital role in the product processing process. The usage of fixture on the fixture board depends on the customer's characteristics. We, Kable-X, recommend the following. For the products with low frequency of drawing design changes, stable order quantity and more auxiliary materials (buckles, pipe clamps, etc.) in the wiring harness, it is suggested to use the wiring harness fixture board with fixture, which can make the processing process consistent and the product processing quality stable. In view of the products with high frequency conversion on drawings, unstable order quantity and few auxiliary materials (buckles, pipe clamps, etc.) in the wiring harness, it is not recommended to use the wiring harness fixture board with fixture. The design changes are very frequent, and the order quantity is unstable, multi-variety, multi-batch, and single order capacity is small, resulting in a decrease in the utilization rate of fixture and a sharp increase in the input of process fixture cost. The wiring harness fixture board can be optimized from common plastic profiles or wooden plates into steel plates, and the fixture can be fixed by selecting flexible fixtures as the base to realize rapid production change. Different product structures or OEMs have a great influence on the production and processing mode. If the product structure is relatively simple, it can save the company's internal labor cost, operation management cost and quality management cost.