Wire Harness Processing Flow Explanation

                                                                 Wire Harness Processing Flow Explanation

 

The process of wire harness processing may have different names in different wire harness factories, but it generally consists of the following main process nodes: incoming inspection and storage, cutting, crimping, assembly, testing (visual/dimensional/electrical), and packaging.

 

Wire Harness Processing Flow

Each process has inputs and outputs, and relevant documents need to be prepared to guide the corresponding production processes.

 

The cutting table, also known as the cutting and crimping detail table, contains various process parameters and requirements. In the production process of wire harnesses, the cutting table is ultimately used to guide the operations of the cutting and crimping processes and to guide the production process in the workshop.

 

Each process also requires inspection, and batch production can only proceed after passing the inspection. Monitoring is necessary throughout the process. For example, in the cutting process, a first piece needs to be made. Only after the parameters such as the length of the first piece and stripped ends pass the inspection can batch cutting take place.

 

Cutting (Material Removal) Process

 

Definition: Cutting involves the process of cutting, stripping, and bundling different specifications of wire conductors according to the length, color, wire material, and wire diameter specified in the process documents based on the design drawings.

 

Process: Prepare materials → Adjust equipment → First piece inspection (measurement of wire length, stripped ends) → Hand over to QC for inspection → Batch production (in-process and final inspection with 100% self-inspection) → Organize wires → Place in transfer trolley or transfer box → Ready for transfer.

 

Inspection: In the cutting process, process parameters such as wire length, fully stripped and half-stripped end lengths, and opening lengths need to be measured (using a ruler, caliper).

 

Semi-automatic and fully automatic crimping process

 

Definition: Crimping is the process of joining wires and terminals together.

 

Process: Prepare materials → Adjust equipment → Produce a first piece → First piece inspection (measurement of crimp height, crimp width using a micrometer, tension test) → Batch production (in-process and final inspection with 100% self-inspection of crimp quality) → Place in transfer box or transfer trolley for transfer.

 

Inspection: In the crimping process, various process parameters such as the presence of R angles, visible range of core wire and insulation, damage to core wire pressure points and insulation pressure points, and crimp distortion need to be measured.

 

Assembly Process

 

Definition: Assembly involves the process of combining semi-finished products obtained from cutting or crimping with other components such as protective sleeves, PVC pipes, corrugated pipes, fiberglass tubes, rubber parts, etc., to form new semi-finished products. (Process design includes assembly drawings, personnel calculation based on workstations and working hours). Assembly can also be centralized or performed on the production line.

 

Process: Prepare materials → Insert, listen, and pull three times → Install self-locking mechanism.

 

Inspection: Self-inspection is performed based on the process of inserting, listening, and pulling three times.

 

Final Assembly Process

Final assembly is the process of combining the semi-finished products obtained from cutting or crimping, and the assembled semi-finished products, with other materials to form the final wire harness product. (Note: During the assembly process, attention should be paid to branching direction, wire harness length, whether PVC tape winding meets the required standards, and whether the wire harness is wound according to the fixture board requirements). The wire harness is bundled with tape or zip ties.

 

Inspection Process

The inspection process mainly includes visual inspection, accessory installation inspection, dimensional inspection, 100% electrical inspection, and image inspection.

 

100% electrical inspection, as well as visual inspection, dimensional

 

inspection, and branch direction inspection, are required for each finished product. Image inspection is mainly used to check the position of fuses and relay connections in wire harnesses with fuse boxes to ensure their correctness. It also involves checking the torque of bolts in the fuse box.

 

Packaging Process

Packaging involves organizing and boxing the wires neatly.

 

Expand and seal the box → Pack and arrange neatly → Tape seal the box → Affix the certificate of compliance and serial number → Apply adhesive tape → Store in the warehouse.