Wire harness process and production
1, Wire harness process
After the online beam two-dimensional product drawing comes out, it is necessary to arrange the production process of the wire harness, and the process is inseparable for the service. Therefore, the two are combined and analyzed together.
(1) Open line process
The opening line is the first station for wire harness production. The accuracy of the wire opening process is directly related to the entire production schedule. Once an error occurs, especially if the opening size is short, it will lead to rework of all stations, which will take time and effort to affect production efficiency. Therefore, in the preparation of the opening process, it is necessary to reasonably determine the opening size and the size of the wire according to the requirements of the drawings. Create an opening operation manual and create a process tracking card.
(2) Crimp process
After the opening of the second production station, determine the crimping parameters according to the terminal type required by the drawings, and make the crimping operation manual. For the special requirements, indicate and train the operator on the process documentation. For example, some wires need to pass through the sheath before they can be crimped. It needs to be pre-assembled and then returned from the pre-installed station and then crimped. Also, the puncture-type crimping uses a special crimping tool. The crimping method has good electrical contact properties.
(3) Pre-installation process
In order to improve the assembly efficiency, complex wiring harnesses must be equipped with pre-installed stations. The reasonableness of the pre-installation process directly affects the efficiency of the total assembly and reflects the technical level of a craftsman. If the pre-installed part of the assembly is too small or the assembled wire path is unreasonable, the workload of the total assembly personnel will be increased, and the speed of the assembly line will be slowed down. Therefore, the process personnel should often stay at the scene to continuously summarize the experience, so as to prepare a reasonable production process. .
(4) Assembly process
According to the assembly platen designed by the product development department, the tooling equipment and material box specifications are designed and the number of all assembly sheaths and accessories are attached to the material box to improve assembly efficiency. Compile the assembly content and requirements of each station, balance the entire assembly station to prevent a situation where the workload is too large and pull down the entire assembly line speed. In order to achieve a work station balance, the craftsman must be familiar with each operation and measure the working hours on site, and adjust the assembly process at any time. The wire harness process also includes the preparation of material consumption quota schedules, working hours calculations, and worker training.
2, The inspection of the wire harness
In order to ensure the quality of the wire harness, the inspection of the wire harness also runs through every part of the production. Since the wire harness mainly serves as a connection, the terminal crimping requirements are very high. See the pull-out force specified by the wires of different wire diameters as shown in Table 3 below. Must not be lower than the value in the table
When a contact or a terminal is connected to two or more wires at the same time, the wire with a larger cross-sectional area is selected to measure the tensile force. At the final inspection, the wire harness mainly checks the size and conduction energy. The tape measure can be used to check whether the size of each branch of the wire harness meets the requirements of the drawing; in addition to the very simple wire harness, the conduction performance is detected by using the conduction table, which is a preset. A microcomputer detection instrument for determining the test procedure. Before testing, input the number and name of the test harness, so that when the corresponding harness is connected according to each corresponding jack, the circuit continuity check can be performed. If there is a fault, it can be displayed through the display of the microcomputer. Prompt for inspectors.
3, Bus technology
There are two general methods of car bus control in the world: LONWORKS bus and CAN bus. Either purpose is to improve the reliability of the harness, reduce the number of conventional wires, and achieve digital transmission of circuit signals. The German company BOSCH has developed the CAN bus protocol, which can be used for the transmission of various signals and has two transmission rates of 10K-100K and 100K-1M baud rate. Due to the generation of bus technology, related automotive electrical components are also designed and developed based on the bus protocol, so that data can be interactively transmitted according to a predetermined priority level under a common transmission protocol.
The above news is reported by the Konnra Electronic Harness Division.
After the online beam two-dimensional product drawing comes out, it is necessary to arrange the production process of the wire harness, and the process is inseparable for the service. Therefore, the two are combined and analyzed together.
(1) Open line process
The opening line is the first station for wire harness production. The accuracy of the wire opening process is directly related to the entire production schedule. Once an error occurs, especially if the opening size is short, it will lead to rework of all stations, which will take time and effort to affect production efficiency. Therefore, in the preparation of the opening process, it is necessary to reasonably determine the opening size and the size of the wire according to the requirements of the drawings. Create an opening operation manual and create a process tracking card.
(2) Crimp process
After the opening of the second production station, determine the crimping parameters according to the terminal type required by the drawings, and make the crimping operation manual. For the special requirements, indicate and train the operator on the process documentation. For example, some wires need to pass through the sheath before they can be crimped. It needs to be pre-assembled and then returned from the pre-installed station and then crimped. Also, the puncture-type crimping uses a special crimping tool. The crimping method has good electrical contact properties.
(3) Pre-installation process
In order to improve the assembly efficiency, complex wiring harnesses must be equipped with pre-installed stations. The reasonableness of the pre-installation process directly affects the efficiency of the total assembly and reflects the technical level of a craftsman. If the pre-installed part of the assembly is too small or the assembled wire path is unreasonable, the workload of the total assembly personnel will be increased, and the speed of the assembly line will be slowed down. Therefore, the process personnel should often stay at the scene to continuously summarize the experience, so as to prepare a reasonable production process. .
(4) Assembly process
According to the assembly platen designed by the product development department, the tooling equipment and material box specifications are designed and the number of all assembly sheaths and accessories are attached to the material box to improve assembly efficiency. Compile the assembly content and requirements of each station, balance the entire assembly station to prevent a situation where the workload is too large and pull down the entire assembly line speed. In order to achieve a work station balance, the craftsman must be familiar with each operation and measure the working hours on site, and adjust the assembly process at any time. The wire harness process also includes the preparation of material consumption quota schedules, working hours calculations, and worker training.
2, The inspection of the wire harness
In order to ensure the quality of the wire harness, the inspection of the wire harness also runs through every part of the production. Since the wire harness mainly serves as a connection, the terminal crimping requirements are very high. See the pull-out force specified by the wires of different wire diameters as shown in Table 3 below. Must not be lower than the value in the table
3, Bus technology
There are two general methods of car bus control in the world: LONWORKS bus and CAN bus. Either purpose is to improve the reliability of the harness, reduce the number of conventional wires, and achieve digital transmission of circuit signals. The German company BOSCH has developed the CAN bus protocol, which can be used for the transmission of various signals and has two transmission rates of 10K-100K and 100K-1M baud rate. Due to the generation of bus technology, related automotive electrical components are also designed and developed based on the bus protocol, so that data can be interactively transmitted according to a predetermined priority level under a common transmission protocol.
The above news is reported by the Konnra Electronic Harness Division.
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