The Production Process of Electric Vehicle Wiring Harness

1. Stripping. It is important for a perfect Cable Assembly. The accuracy of wire stripping is directly related to the entire production schedule. Once errors occur, especially if the wire size is too short or too long, it will lead to rework of all stations, which is time-consuming and labor-intensive and affects production efficiency. Therefore, when stripping the wire, it is necessary to reasonably determine the opening size of the wire and the size of the stripping head according to the requirements of the drawing and the terminal to be punched.
2. Crimping. Determine the crimping parameters according to the terminal type required by the drawing, and make the crimping operation manual. For those with special requirements, it is necessary to indicate on the process document and train the operator. For example: some wires need to pass through the sheath before they can be crimped. It needs to pre-install the wire and then return from the pre-installation station to be crimped. There are also special crimping tools used for piercing crimping. This crimping method has good electrical contact performance. And be sure to test the tension value of the terminal, if the tension does not meet the requirements, you need to re-adjust the crimping die.
3. Pre-installed. First of all, the pre-assembly process operation manual must be compiled. In order to improve the efficiency of assembly, a pre-assembly station must be set for complex wiring harnesses. The rationality of the pre-assembly process directly affects the efficiency of the overall assembly and reflects the technical level of a craftsman. If the pre-assembled part is too small or the wire path of the assembly is unreasonable, it will increase the workload of the general assembler and slow down the speed of the assembly line, so the craftsman should always stay on the site and keep summarizing.
4. Assembly process. It can compile the assembly platen designed according to the product development department, design the tooling equipment, the specifications and dimensions of the material box, and paste the serial numbers of all the assembly sheaths and accessories on the material box to improve the assembly efficiency. Compile the assembly content and requirements of each station, balance the entire assembly station to prevent a bit of excessive workload and pull down the speed of the entire assembly line. To achieve station balance, the craftsmen must be familiar with each operation and measure the working hours on site, and adjust the assembly process at any time.
The production of automotive Wiring Harness is mainly divided into two methods: crimping and forming. And we must fully inspect the product, test the continuity, resistance, voltage, etc. of the wire to ensure the yield of the product and prevent defective products from entering the market.