Quality control in the production of automotive wiring harnesses

Quality control in the production process of automotive wiring harness Structure and function of wiring harness Automotive low-voltage wiring harness is composed of wires, connectors, terminals, studs, sheaths, adhesive tapes, corrugated pipes, PVC pipes, brackets, heat-shrinkable sleeves and fuse boxes. assembly composed of materials. The wiring harness is connected to each other and transmits electric energy and electrical signals to the electronic appliances on the car, which has the image title of "car nerve". Each wiring harness has different functions in the whole vehicle, so it is divided into main wiring harness, cockpit wiring harness, instrument panel wiring harness, door wiring harness, ceiling wiring harness, engine wiring harness, etc. Common wiring harness defects Common wiring harness defects include terminal withdrawal, wrong relay/fuse assembly, wrong buckle position, poor relay operation, short circuit, damaged insulation skin, open circuit, poor contact, etc. In addition to the natural factors that cause the failure (long service life, oxidation/deformation of the wire harness end), the damage of the wire harness caused by the failure of electrical equipment, and the subjective human factors when assembling or repairing auto parts, there are many defects in the wire harness. It can be prevented or eliminated during the production process. Quality control during production The general manufacturing process of automotive wiring harness includes incoming material inspection, raw material storage, wire cutting, crimping, ultrasonic welding, heat shrinkable sleeves, stranded wires, terminal plugging, assembly of coverings and accessories (felt, adhesive tape, PVC pipe, bellows, clamps, cable ties and brackets, etc.), assembly, wiring harness inspection (appearance, size, electrical properties and air tightness, etc.), packaging and warehousing. The flow diagram is shown in Figure 1. Automotive wiring harness manufacturers say that on the basis of personnel training, equipment maintenance, routine inspection and other guarantees, the quality of wiring harnesses will still fluctuate due to many reasons. Therefore, through professional advantages and experience feedback, we have refined key monitoring points for each process and implemented them at suppliers to help suppliers improve their first-time off-line qualification rate and 0 km quality performance. 3.1 Tangent-inkjet-crimping 1) Equipment ① The application parameters of the equipment are set by the process or production supervisor and cannot be manually interfered by the operator; ② The interface for setting parameters on the machine is closed to the operator; ③ Whether it is automatic crimping equipment or semi-automatic crimping equipment, it must be equipped with pressure monitoring devices; ④ Once an abnormality occurs, the equipment will automatically destroy the non-conforming crimping or automatic locking system. 2) Process ① Confirm that the wire is not bent, knotted, stressed or falling on the ground; ② Manual re-cutting, peeling and crimping operations are not allowed, and there are no prohibited tools (scissors, pliers, etc.) in the workshop; ③ Before starting crimping, CFM (Crimp ForceMonitoring) teaching should be carried out; ④ The crimped terminal is protected by a wire cup, wherein the terminal has no contact with the bottom of the wire cup, and the wire cup cannot be tied to the terminal, but to the insulator; ⑤ In the case of double crimping, if it is stacked crimping, the wire with smaller cross-sectional area should be placed below; ⑥ If crimped in parallel, the cross-sectional areas of the two wires should be the same.

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