The entire process of Terminal Wire Harness Processing can be clearly divided into the following steps:
1. Incoming material acceptance
Wire acceptance: Use environmental certification test equipment to conduct environmental testing on all incoming materials required for the harness to ensure that they do not contain harmful substances such as lead, mercury, cadmium, brominated biphenyls, and polybrominated diphenyl ethers.
Terminal acceptance: Check whether the material, shape, and geometric dimensions of the terminal meet the relevant technical standards.
2. Wire cutting (opening)
Put the required processed wire on the transfer wire rack and fix it, and use the wire cutting machine to cut the wire into the required length.
Before the wire opening process, carefully study the wire harness drawing, reasonably determine the wire opening size and stripping head size according to the drawing requirements, and prepare the wire opening operation manual and process tracking card.
3. Stripping
Use tools such as wire strippers or wire strippers to strip the insulation layer of the wire to expose the required conductive wire core.
Pay attention to moderate strength during stripping to avoid damaging the wire.
4. Soldering
Adjust the tin furnace to the temperature given in the SOP (such as 300±20℃) for the wire with the outer skin removed.
When tinning, the core wire must be sent vertically into the tin furnace, and the wire must be taken out immediately when the core wire is in place.
5. Terminal crimping
According to the process requirements for producing terminal wires, use a crimping machine to crimp the terminals.
Ensure that the tensile force meets the standard during the crimping process to ensure a firm connection between the terminal and the wiring harness.
6. Assembly and packaging
Assemble the crimped wiring harness with components such as the housing.
Use insulating sleeves to encapsulate the terminals and wire parts to increase the safety and durability of the wiring harness.
7. Quality inspection
Perform visual inspection and electrical testing on each processed wiring harness to ensure that the processing quality meets the requirements.
If there are defective products, rework or scrap them.
8. Recording and tracking
Keep records of each processed wiring harness, including the number, specification, and usage location of the wiring harness, for later tracking and management.
The entire process of Terminal Wire Harness Processing requires strict control of each link to ensure stable and reliable processing quality and product performance.
