The wire harness production process mainly includes the following steps:
Design and planning: Design and plan the layout, length, connecteurs, etc.. of the wire harness according to the requirements of electronic and medical equipment manufacturers and the characteristics of vehicle models. This step needs to consider factors such as the reliability, safety, maintainability and cost of the wire harness.
Purchase and prepare materials: According to the design requirements, purchase appropriate wires, connecteurs, insulation sleeves, protective sleeves and other materials. These materials need to comply with relevant standards and specifications and undergo quality inspection and verification.
Cutting and stripping wires: According to the design requirements, cut the wires into appropriate lengths and strip the insulation layers at both ends of the wires for connection.
Assembly and connection: According to the design requirements, connect the wires to the corresponding connectors or terminals. This step requires precise connection and insulation processing to ensure the reliability and safety of the wire harness.
Insulation and protection: At the connection points and vulnerable parts of the wire harness, take measures such as insulation sleeves and protective sleeves to protect the wire harness from external environment and physical damage.
Testing and verification: Test and verify the completed wire harness to ensure its electrical performance and reliability. This includes testing resistance, insulation resistance, electrical connectivity, etc..
Packaging and delivery: The finished wire harness is packaged and delivered to the automaker or supplier for installation and use on the vehicle production line.
Wire harness processing test is to ensure the quality and safety of wire harness, ensure that the wire harness can work normally during use, reduce the occurrence of faults and eliminate some safety hazards.
The main test items for wire harness processing are: resistance test, size test, wire harness continuity test, capacitance test and contact resistance test.
The resistance test is to test whether the resistance value in the wire harness is within the specified range to ensure the normal operation of the wire harness.
Wire harness continuity detection is the most basic test item to ensure the quality and reliability of the wire harness and ensure that the wire harness can work normally during use.
The continuity tester can detect unqualified products such as open circuit, short circuit, dislocation, etc.. in the wire harness, so as to rework.
Capacitance test mainly detects the capacitance in the wiring harness to prevent wiring harness failure and short circuit caused by capacitance failure in the wiring harness.
Contact resistance test is to judge the quality and stability of contact points by measuring contact resistance. Ensure the resistance of contact points in the wiring harness.