New technology of wire harness production for engineering vehicle

Domestic and foreign market demand for engineering vehicles gradually pick up, wiring harness orders are also coming, but the traditional production model can meet the market demand, through the implementation of new technology, wiring harness manufacturing enterprises to improve production capacity, reliable quality, in the fierce competition in the wiring harness sales market in a small losing ground.

Now the author will analyze the new process in the wiring harness manufacturing process:

Step 1 Log out

The traditional downline is generally the use of semi-automatic downline machine, if more simple, manual downline situation also exists, which not only reduces the production speed, but also increases the labor intensity of the operator.

Today, the operator can use an automatic crimping machine to achieve offline according to the production line, the line number, line color, line diameter, cutting line length, line end brake line length, line end processing, whether to wear a waterproof plug, middle brake position and length and other information into the computer, the automatic crimping machine output semi-finished products.

According to the wire diameter of the wire, the operator inputted the corresponding line number word height parameter and line number spacing parameter for the inkjet color in addition to the black line, the color inkjet code is mainly used for the special requirements of individual OMs on the black ground line. In addition, in order to distinguish the confusing line number, For some line number groups, such as 18 and 81, it is generally necessary to add a "-" after each line number to distinguish, such as 18- and 81-.

After adjusting the inkjet parameters, the operator will enter the line number, line color, line diameter, cutting line length, line end brake line length, line end treatment, whether to wear waterproof plugs, middle brake position and length and other information in accordance with the production line:

(1) For the wire that needs to be crimping the terminal, the operator shall replace the corresponding wire and end f mold specifications according to the production line, adjust the pressure so that the tension between the terminal and the wire reaches the specified range, adjust the supply speed of the waterproof plug, conduct at least 3 tension tests, and record the test process. If the test is qualified, continue to adjust the pressure; If it meets the crimping tension standard, it can be crimped down in batches.

(2) For small wire that requires terminal crimping, the operator can install the corresponding wire reel according to the production line, adjust the total length of the production line, the length of the brake at both ends, the knife value and the rotation value of the brake skin, set the daily standard production capacity and the number of bundles, confirm the first qualified product, and carry out mass production.

(3) the brake straight is a headache for wire harness manufacturing enterprises, manual brake speed is slow and easy to cause injuries. Now the operator can operate an automatic offline crimping machine to achieve the brake function, and the wire diameter can be from 0.5mm² to 6mm², which greatly reduces the labor intensity of the operator. More than 6mm² of the wire use frequency is low and the automatic brake effect is poor, now still use manual brake.

2. Parallel welding

Traditional parallel wire welding for manual terminal cold pressing, wire diameter is the use of tin welding, time-consuming and pollution in order to overcome the traditional difficulties, operators use ultrasonic welding machine welding, and then heat shrink tube heat shrink welding spot ultrasonic welding machine mainly uses mechanical vibration into energy to fuse copper to each other, to achieve welding day.

In order to improve efficiency, the operator can use the heat shrink tube cut into a disc by the pipe cutting machine in advance. After the welding work is completed, the operator directly selects the suitable heat shrink tube on the station to cover and spot, and then blows the heat shrink tube with a hot air gun to make the welding spot waterproof and dust-proof. It is worth mentioning that in the process of trial operation of the new process, we also tried the plastic machine to protect the welding spot. Make the solder joint into a box or ellipsoid and install a sealed solder joint.

3. Laser engraving

The object of laser engraving is mainly the connector, which is to mark the code of the four wire ends in the wiring harness, so that the wiring harness is easy to identify when loading and maintenance, the identification connector in the traditional process is only written by the operator using an oil pen, the font is small and easy to identify the wrong, and the mark naturally falls off over a long time, which increases the difficulty of the maintenance personnel when the wiring harness is in trouble.

In order to solve such problems, the operator uses the laser marking machine docking plug-in engraving in order to solidify the docking position of the connector, the operator uses the connector to fix the module docking plug-in marking today, the code of the connector in the harness is standardized, and the customer is very satisfied.

4. Repackage

Subassembly is used in mass wiring harness production, this process looks small at first glance, but for mass production and C, its role can be ignored in traditional production, wiring harness production is a little of the concept of subassembly, the operator just put the wire according to the drawing to apply the wire one by one to the pegboard, bandage the tape after the end of the application, cut the end of the wire 4 wiring harness need to waste at least a few meters. When the concept of subassembly is proposed, the wiring bundle is disassembled as far as possible, and the crimped end r wire that flows out of the downline process can be classified and inserted into the connector according to the technical file, and then flowed into the wiring process as a whole (product identification through the process flow sheet) for mass production, which can make the operator form a habitual action. The possibility of inserting the wrong hole position of the end r is reduced to a small amount to ensure the quality of the subsequent process.

Step 5: Wiring

The traditional wiring operator has to nail the board according to the drawing, and the wire is easy to loose and dislocation when wiring. Now, the wiring harness enterprise converts the drawing into a 1:1 wiring diagram, that is, the wiring harness physical drawing made according to the actual size of the standard. Then the 1.1 wiring pin to the wiring board for the use of wiring board like the selection of 1.8 m *0.9 m, 2.4 m *0.9 m and 3.6 m *0.9 m three specifications of wood, more human wiring harness can be taken from the three specifications or superposition the combination of 4 branch points fixed fork, 4 wire ends using the fork and plastic wire clamp to fix the wire. The advantages of the traditional napping and fixing new process are accurate size, saving wires, reducing the work intensity of operators, and improving production efficiency.

When wiring, the operator first needs to check whether the cable fork of the wiring board is firmly installed and whether the Angle is correct; The wiring sequence is generally ground priority (more parallel points), and then arrange the distribution harness and other wires. Be sure to ensure that the wiring harness is neat and straight after the wiring is completed, the wiring personnel use black insulation tape for preliminary wrapping to fix it. The dressing is required to be beautiful, reliable, and no bulge.

Step 6 Wrap

When the traditional process is wrapped, the effect of the same operator is small, and the inspector is also small to determine whether it is qualified, and can only evaluate the experience to determine that the product is often "ICI small corrugated pipe with the same aperture is wrapped in the same branch, resulting in small thickness and thickness, and the product quality is affected.

Now, the operator refers to the process documents and the drawings of the standard bellows type for operation. The operator must first check the applied wiring harness without error, then select and intercept the bellows of the appropriate size according to the requirements of the drawings, and then wrap the bellows from the connector end to the main ten direction, and wrap the open bellows tightly with insulation tape after Z. To ensure smooth appearance, branch points must be wrapped with insulation tape. No exposed wires occur. At the connector end, the bare wire length specified in the drawing must be set aside, and the bare wires must be neat.

7. Secondary crimping

One time crimping refers to the supplementary crimping of the remaining uncrimped terminal by the operator using the semi-automatic crimping machine. One time crimping requires the operator's ability to identify the end r, and the first time crimping for 4 days needs to do the first tensile test, and the semi-automatic crimping machine needs to be cleaned before work.

The semi-automatic crimping machine is distinguished according to the end r mold of the small with the small with the die is made according to the small with the terminal by the crimping machine manufacturer. In actual operation, the operator chooses the appropriate crimping machine for production according to the guidance of technical documents and production experience.

After the terminal crimping is completed, the operator should check the appearance of the end r crimped, if small qualified, it needs to be trimmed.

8. Plug-ins

The external quality feedback rate of the plug-in process is very high, and the problems mainly focus on three aspects :(1) the use of the connector model is wrong; (2) The terminal insertion sequence is wrong; (3) The terminal is not firmly inserted; (4) Auxiliary materials such as blind plugs or fixed pieces are missing

In order to solve this problem, the wiring harness enterprise has formulated operation instructions to provide detailed guidance for the four production steps of the operators, implement the assessment system for the plug-in process personnel, strictly refer to the technical document operation, and force to strengthen the consciousness of the personnel. In order to strengthen the identification of the operators' docking plug-in, we put forward the concept of image drawing on the product drawings. That is, the outgoing end (combined with the connector) or the incoming end (the direction of the terminal insertion connector) are defined, and the connectors on the drawing are drawn as one-dimensional connectors, so that everyone reduces the possibility of incorrect insertion sequence.

9. Inspection

The traditional inspection is generally used to check the on-off situation at both ends of the universal agricultural wire, in addition, the small wire harness calibrator is often used for batch wire harness production, the test speed and accuracy of the first two methods are as small as the aeroelastic calibrator, the actual calculation proves that, The speed and accuracy of the aeroelastic calibrator are beyond doubt. For the instrument harnesses with many branches and small ones suitable for the aeroelastic calibrator, the previously used small calibrators have also been replaced by special instrument calibrators.

10. Summary

The above is the author's simple analysis of the new process content used in the production process of engineering vehicle wiring harness Although the new process of wiring harness is much more advanced than the traditional process, there is still room for progress and a broad prospect of engineering vehicles! lJ field and Dian wire harness manufacturing enterprises need to improve their own process capabilities to achieve more human value and meet market demand.