1. Blanking
Blanking is to cut and peel the original wire (usually coiled wire or barrel wire) according to the process requirements.
2. Pre-assembly
The first sub-assembly is to prepare for crimping. The processes usually include: threading the silicone tube, threading the pull-back connector and threading Waterproof plug and stripping of three-core and two-core wires.
If some relatively large terminals need to pass through a small silicone tube (such as a silicone tube with a diameter of Φ6), the silicone tube must be threaded first at the disassembly point, and then the terminal is crimped, otherwise As a result, the terminal of the silicone tube is too large and cannot be pulled.
For pull-back terminals, such as 1216, 2190 and some other connectors, the wire must be inserted into the connector first, and then the terminals can be pressed.
At this point, the subassembly process should be particularly careful, requiring technicians to have a good understanding of connectors and terminals.
When disassembling, special attention should be paid to the fact that if the process requires the three-core wire to be cut or fully wrapped with PVC, it must be operated according to the process.
Because the insulation layer of some three-core wires is made of conductive materials, if it is not cut or protected, it will easily lead to leakage or fire, and the consequences will be very serious.
3. Crimping
Crimping is a way to use mechanical equipment such as a crimping machine to press the terminals and original wires together so that they can function as a connection.
When crimping general terminals, we should pay attention to the following points:
1) Do not operate at will before the tooling personnel have debugged the mold.
2) When crimping, we must first test the pulling force and the height of the terminal. In this way, we can use the measured actual tension value and height value as a standard to determine whether the product meets the requirements.
3) If there are other abnormal factors such as the terminal getting stuck in the jaw during the crimping process, the power supply to the motor should be cut off immediately, and the relevant person in charge should be informed in a timely manner.
4) When crimping, avoid whispering, concentrate your thoughts and work carefully.
5) Be sure to cut off the power supply after the crimping is completed to avoid unnecessary work injuries.
6) Equipment engineers should check whether there is any damage during the mold exchange process. If the crimping jaw is damaged, it should be replaced in time. The mold must be protected at ordinary times, the accumulated chips should be cleaned in time, oiled and checked and debugged regularly. If there is a problem with a mold, a comprehensive inspection should be carried out.
After the crimping process is completed, some terminals require heat shrinking. Heat shrinking is to put the heat shrink tube on the exposed wires or terminals and bake it evenly on the air gun until it wraps the terminals or exposed wires.
Heat shrink tubing can be divided into single layer and double layer. Single layer heat shrink tube is mainly used for grounding, while double layer is generally used for riveting points. Their functions are the same. ——Protect and prevent leakage.
During the baking process of the heat shrinkable tube, attention should be paid to continuous turning and baking. There should be no carbonization on the surface of the wire body and the heat shrinkable tube. If it is a double-layer heat shrinkable tube, start from the heat shrinkable tube. The liquid flowing out of the tube should fully and evenly wrap the wire body.
Sometimes the ends will be bent and deformed during the baking process. This is not allowed in principle, but it is difficult to avoid in actual operation, so as long as it does not affect the use, the bending is not too serious. All are normal.
4. Assembly
It is to arrange, wire, wind, and wrap the semi-finished products that have been pressed and assembled according to the positions and lines specified on the chopping board, and finally get The process of finished product.
It is best to print the assembled chopping board on photo paper.
The chopping board drawing should include the following:
The length of each section;
The size, length and location of the corrugated tube and silicone tube;
The position of each connector and the wire number, specification, color, hole location, etc. of the wires on the connector;
The direction distribution of the wires;
< p>Nut positioning hole;Precautions and special technical instructions, etc.
Operators should strictly follow the regulations on the chopping board for disassembly and assembly during the operation, and should promptly report any problems to the technicians if they encounter any problems. If you accidentally insert the wrong terminal during operation or encounter special circumstances, please notify the relevant person in charge as soon as possible to solve the problem.
When plugging terminals, you should follow the following requirements: one plug, two plugs, and three pulls.
Some terminals have positive and negative orientations when inserted, so if you encounter difficulty in insertion, you should adjust the insertion direction of the terminal in time and do not press it in hard.
You will hear a slight "pop" sound after normal insertion. When you hear the sound, don't exert any more force, but pull back to see if there are any signs of looseness.
If the terminal cannot be inserted no matter which direction it is turned, it may be that the terminal is pressed incorrectly or the connector is delivered incorrectly. At this time, the technician should be notified as soon as possible for detailed verification to ensure Determine its correction plan.
The picture above shows a part of the chopping board pattern. The chopping board diagram contains a lot of information. The operator must take good care of the peritoneum on it and is strictly prohibited from scribbling with sharp objects such as knives. The chopping board is made of pressed sawdust board, so it should be lifted lightly and not hit.
5. Final assembly
Final assembly is a process immediately following assembly, including the large bellows on the upper trunk, the winding of the trunk and some small bellows, etc.
The most important thing in this step is to coordinate the division of labor with the assembly, because it is difficult to make a clear boundary on who will be responsible for installing the bellows. The bellows on the main trunk or the diameter exceeds Φ13 The bellows can be considered to be completed by the final assembly.
6. External inspection
The job of external inspection is to check whether the size, appearance, etc. of the product are qualified. The requirements for external inspection are as follows:
First, there can only be positive deviations in size, but no negative deviations, that is, they can only be long but not short. If they are short, they will not be able to be pulled during installation. situation, and most often cannot exceed 10mm.
Second, the exposed wire body outside the corrugated tube or silicone tube cannot exceed 5mm.
Third, there should be no excessive "explosion of the wire" (the corrugated tube cannot wrap the wire body).
Fourth, whether the terminals are obviously not in place.
In actual operation, it is not necessary to measure every product with a tape measure. We only need to measure an accurate one, and then use this one as a reference sample. Each subsequent one will be compared with this one. If there is no obvious difference in length, it is qualified.
7. Electrical inspection
Electrical inspection is to check whether the circuit is smooth with the help of some electronic testing equipment.
Electrical inspection equipment may vary from manufacturer to manufacturer. Almost all current inspection equipment incorporates computer assistance, which not only makes programming convenient, but also speeds up the efficiency of inspection.
Summary: The above introduces the production process of the entire product, which may be different for the actual production factory. However, as far as the entire process flow is concerned, it is still very much the same.