What to look for when processing technology for electronic custom wire harnesses Repair of large connectors in custom wire harnesses

What processes should be paid attention to in the processing of electronic customized wiring harness? In the processing of electronic wiring harness, there are problems such as broken wire core, terminal wire terminal falling off easily, false welding of electronic wiring harness and wiring harness connector not being threaded in place. Some of these problems are caused by human misoperation, some are caused by wiring harness processing equipment, and some are caused by wiring harness raw materials. These problems will affect the quality of wiring harness. The terminal wire of the 1、 falls off, which is just the opposite of the situation of the third party above. The terminal machine is too loose when adjusting the machine, which causes the terminal to be unable to firmly wrap the harness. The harness connector of the 2、 is not inserted in place, which mainly occurs during the assembly of the harness. The harness of the electric vehicle is not inserted in place when it is inserted into the rubber shell of the connector. Under normal circumstances, there will be a "click" sound when it is inserted in place. In order to ensure that it is in place, it is necessary to pull back, that is, hold the connector with one hand and pull the wire with the other hand. Be careful not to use too much force to avoid breaking the harness. The electronic wiring harness of the 3、 has poor soldering. When the wiring harness is welded and processed, the wire core is not tinned enough, or the contact surface of the two wire cores is too small, the phenomenon of poor soldering will occur. Because the welding position is to be covered with an insulating sleeve, the appearance can not be seen. Some problems can be found in the quality inspection process. If the wiring harness is installed on the equipment, it will easily fail. There are three reasons for the breakage of the wire core of the 4、 electronic wire harness: First, the quality of the raw material cable of the wire harness is not up to standard, the flexibility is not enough, or the wire diameter is not enough; Second, when the wire harness is cut, the wire feeding roller presses the wire too tightly, causing the wire core to be broken; Third, when the wire harness is crimped to the terminal, the machine is adjusted too tightly, and the pressure under the blade is too large, causing the core wire to be broken.

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1. Repair of general large joints: cut the two sides of the broken glue into a slope with an angle of 45 ° along the circumference of the plastic layer with a knife, take a clean plastic pipe with the same color and thickness, length and outer diameter as the broken glue, cut one side of the pipe into an opening with an angle of 45 ° along the axis, and tie it at the broken glue with a thin copper wire at an equal distance. Then the same plastic strip is bonded and welded under the welding of a hot air plastic welding gun, and then a copper sheet is compacted, pressed and flattened. It is qualified if there is no breakdown after spark machine test. 2. Repair of large joints in the production process: In the production process, due to other reasons, the production is temporarily stopped, the sheath is disconnected, and the joints can be continuous. The method is to cut the plastic sheath into a circular slope with an angle of 45 °, retreat to the head, extend into the die core mouth for 30 mm, and then run the glue. After running the glue, the crew members cooperate with each other to connect the plastic layer by hand when driving, and then shape and repair it. 3. If the cable sheath has quality defects at a longer length from one end, while most of the sheath at the other end is in good condition, and the cable length is fixed, the repair method of large joints in the production process can also be used. Only after the sheath at one end with quality defects is removed, a larger die is selected on the extruder, the sheath at one end is removed according to the process, the traction speed is gradually increased at the large joint, so that the sheath at the joint is gradually thinned and wrapped on the original sheath cut into a slope shape, and the sheath is shaped and repaired after being removed from the extruder.

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