Wire harness factory production process: material, the first sub-assembly (pre-assembly), crimping, assembly, assembly, general assembly, external inspection, electrical inspection.
1, the material
The material is the original wire (usually coiled wire, but also barrel wire) in accordance with the requirements of the process, truncation and stripping.
Downloading in the material at the time, it should be noted that the deviation is generally adjusted to +10 or so, there can be no negative deviation. Under the feeding machine in the case of material, if there is instability should be timely debugging or maintenance. Under the material machine generally have a fan for heat exhaust, if the temperature of the discharge is abnormally high, the machine should be turned off and then checked.
The cutter of the lower feeder should be replaced in time after a long time of use and wear. Under the material in the material, should be labeled, labeling should be neat and clear handwriting, labeling content, including the use of the product model, the length of the original line, the length of the two ends of the peeling and other information. After the material should be in accordance with the original line area of the location of the specified categories placed in a good.
2, the first sub-assembly (pre-assembly)
The first sub-assembly is to prepare for crimping, usually including the process of: wearing silicone tubes, wear back to pull the plug connector and wear a waterproof plugs and three-core wire stripping of the two-core wire.
Some of the larger terminals, if you need to pass through the small silicone tube (such as diameter Φ6 silicone tube), must be in the subassembly first wear a good silicone tube, after crimping the terminal, not then cause the silicone tube will be too large and pull the terminal.
Pullback terminals, such as 1216, 2190 and some other plugs, you must first thread the wire into the plug, and then wait to press the terminal.
At this point, do the sub-assembly process should be particularly careful, requiring the technician to be very knowledgeable about the inserter and the terminals.
Partitioning should also pay special attention to is if the process requires the three-core wire cut or wrapped with PVC, must be in accordance with the process to operate, because some of the three-core wire insulation layer is used in conductive materials, if not cut or not to protect, it is easy to lead to leakage or touch the fire, resulting in the consequences are very serious.
3, crimping
Crimping is the use of crimping machines and other mechanical equipment will be pressed together with the terminal and the original line, so that it can play a role in connecting a way.
In the crimping of general terminals, we should pay attention to the following points: in the tooling personnel debugging before the mold, do not operate at will. When crimping we must first test the tension and the height of the terminal. So that we can be measured according to the actual value of tension and height value as a product whether to meet the requirements of a standard.
Crimping process if the terminal stuck in the jaws of other abnormal factors, should immediately cut off the motor power supply, and then promptly inform the person in charge. Crimping, do not talk to each other, to concentrate on the mind, serious work. In crimping is completed must cut off the power supply, so as not to cause unnecessary accidents.
Equipment engineers should check whether there is damage in the process of changing the mold, if there is damage to the crimping jaws, should be replaced in a timely manner. Usually must protect the mold, timely clean up the accumulation of debris, regular oil and check debugging, if there is a problem with a mold, should do a comprehensive inspection.
Crimping process is completed, some terminals need heat shrinkage. Heat shrink is to set on the bare wires or terminals on the heat shrink tubing on the wind gun evenly baked until it wraps around the terminals or bare wires.
Heat shrink tubing can be divided into single-layer and double-layer two kinds of heat shrink tubing, single-layer heat shrink tubing is mainly used on the lap, while the double-layer is generally used for riveting points, their role is the same - to protect and prevent leakage.
In the baking process of heat shrink tubing, attention should be paid to constantly turning over the baking, the wire body and the surface of the heat shrink tubing can not have charring phenomenon, if it is a double-layer heat shrink tubing, the liquid from the heat shrink tubing should be sufficiently and evenly wrapped around the wire body.
Sometimes in the baking process will appear at the end of the bending deformation of the situation, which in principle is not allowed, but in practice it is difficult to avoid, so as long as it does not affect the use of the bending is not too serious are normal.
4, assembly
It is the crimped and subassembled semi-finished line in accordance with the location of the board and the line, plate, wiring, winding, wrapping, and ultimately get the finished product process.
The assembled casework is best printed on photo paper. The drawing should include the following contents: the length of each section; the size and length of the bellows and silicone tube and its position; the position of each plug and plug the wire on the wire number, specification, color, where the hole, etc.; the distribution of the line towards the distribution of the nut positioning holes; precautions and its special technical instructions and so on.
Operators in the process of operation should be strictly in accordance with the provisions of the board to the division and assembly, encountered problems should be timely to the technical staff. If in the process of operation encountered accidentally insert the wrong terminal or other special circumstances, should be notified as soon as possible to the person in charge of the solution.
When inserting and connecting the terminals, the following requirements should be followed: one insertion, two listening, three pull back.
Some of the terminals in the insertion of the positive and negative points, so encounter insertion difficulties should be promptly adjusted to the insertion of the direction of the terminal, do not press hard into.
After normal insertion, you will hear a slight "pop" sound. When you hear the sound, don't press harder, but pull back to see if there is any sign of loosening.
If the terminal can not be inserted no matter which direction it is turned, it is possible that the terminal pressure is wrong, or the plug distribution error, at this time should be notified as soon as possible to the technician for a detailed check to determine its rectification program.
5, general assembly
General assembly is immediately after the assembly of a process, including on the trunk on the large bellows, trunk and some small bellows winding. The most important thing in this step is to coordinate the division of labor in the middle with the assembly, because it is difficult to make a clear boundary on who should operate the bellows, and the bellows on the trunk or the bellows with the diameter more than Φ13 can be considered to let the general assembly to complete.
6, external inspection
The work of the external inspection is to check whether the product size, appearance and so on is qualified. The requirements of external inspection are as follows: First, there can only be a positive deviation in size, there can be no negative deviation, that is, there can only be long and not short, short will appear when the installation of the pull can not be the case, and the longest length can not be more than 10mm. second, exposed in the bellows or silicone tube outside the body of the line can not be more than 5mm.
Third, there can not be too much of the "line of violence! " (bellows can not wrap the body of the wire case). Fourth, the terminals have no obvious out of place. In practice, it is actually not necessary to measure each product with a tape measure. We only need to measure out an accurate, and then take this as a reference sample, and then every one of them and this one next to the control, if there is no obvious difference in length, it is qualified.
7, electrical inspection
Electrical inspection is in the help of some electronic testing equipment, check whether the circuit is smooth. The electrical inspection equipment may vary from one manufacturer to another. Nowadays, almost all inspection equipment incorporates the aid of computers, which not only makes programming easier, but also speeds up the efficiency of the inspection.