Harness Assembly Process and Requirements

1. What is a Wiring Harness?

A Wire Harness is a combination of strings of wires and cables used to transmit information signals or operation signals. The binding materials of the Cable Assembly include clips, cables, sleeves, electrical tapes or the combination of these materials.

Second, the assembly process

1. The wire harness sub-material number must be made according to the positioning plate to determine the wire cutting size.

At present, in the process of wire harness assembly, it is often possible to meet the size of sub-materials, but not the size of positioning plate, resulting in a lot of unnecessary waste. The sub-material number should also be electrically measured and fully inspected.

2. Wiring of the harness. (1) tile each sub-material number on the positioning plate according to the requirements of the drawing. (2) when wiring, first of all, one area should be put, and after the sub-materials in a single area are put, the sub-materials across areas should be put. (3) Cross-regional sub-materials should also be simple first, and then complex.

3. Insert PIN (some TER without PIN must be inserted into the corresponding Connector first). Tie line (the position of tie line is according to the positioning plate, and the starting point of tie line is generally at the starting point of double line in the positioning plate).

4. Electrical measurement. (1) Due to the complexity of the assembly line, the test data must be strictly checked. ② The test can only be carried out after being confirmed by PE&QE.

5. Full inspection. ① Check whether the terminal and CONN are within the tolerance zone. ② Check whether the tie ring is even. ③ Check whether the assembly method of parts is correct. 6. Warehousing of wire harness sub-materials. Sub-materials must PASS OQC inspection before subsequent actions can be carried out.

Third, the assembly process requirements

1. After the wiring harness is processed and assembled, all wiring harnesses should be parallel and cannot be moved. However, the tying rope or tying belt can't hurt the wire.

2. When inserting PIN or welding, the core wires should not be intertwined, but they should not be too tight.

3. When wiring, the terminals, HOUSING, D-SUB, IDC and CONN of each sub-material number must be consistent with the marks on the positioning plate.

4. The wires of each sub-material number must be arranged according to the route on the positioning plate.

5. When tying the wire, the rope should move vertically from the bottom of the tying ring.

6. The binding belt should be tight and the tail should not exceed 1 mm..

7. When tying wires, the distance between two tying rings is about 25mm, and the tail of each rope should be kept about 10mm at the end.

8. Each rope should be knotted at the beginning and end.

9. When tying the line, the rope cannot be looped or wound. Do not clamp the connector on the positioning nail, pull the rope hard, fix the thread end of the rope on the positioning nail, and then tie the line. Otherwise, it is easy to cause the terminal to break the core wire or the terminal to fall off.

Fourth, the assembly quality standards

After the wiring harness is assembled into a finished product, it is necessary to detect the wiring conductivity of the wiring harness, and it is required that the wiring conductivity be 100% without short circuit, short circuit and wrong circuit. At the same time, it is necessary to meet the quality standards required by wiring harness customers, and provide safety and quality guarantees when packaging.

Every step of wiring harness assembly inspection of Kable-X should be meticulous, strive for perfection, and standardize operation requirements according to ISO 9001: 2015 quality management system.