(Electrical, Signal) Wire Harness Manufacturing Process

The processing and production process of Electrical connection cable and signal wire harness is divided into the following parts: Cut the wire → strip the wire sheath → brush the wire → twist the wire → dip in tin → terminal crimping → sub-assembly → assembly → electrical testing → appearance inspection → packaging.

(Electrical, Signal) Wire Harness Manufacturing

Long Life (Electrical, Signal) Wire Harness Manufacturing Process

Cut wires
Use automatic wire cutting equipment to cut the wires according to the size required by the process. Arrange the cut wires neatly (50 wires/bundle) and place them in the designated location and label them.

Take off the outer skin of the wire
Install the corresponding blade according to the wire specifications, and adjust the peeling, thread clamping, and thread cutting strokes according to the process indicators. Adjust the size adjustment plate according to the peeling length, place the wire in the middle of the blade, hold the thread head against the size adjustment plate, and step on the foot pedal to peel.

3. Brush the wires
Turn on the power, the electric copper brush turns clockwise, separate the exposed oblique cladding at both ends from the core wire according to the SOP method, and twist the separated oblique cladding (i.e. the ground wire) tightly and straight.

4. Twisted wire
The twisting clamp is complete and the turning force is even. Clamp all the brushed copper wires into the twisting clamp for twisting (the copper wire should be clamped in the middle and lower part).

5. Dip tin
Adjust the tin furnace according to the temperature given on the SOP (300±20℃). Arrange the wires neatly, separate and align the core conductors, and apply flux to the core conductors. When tin dipping, the core wire must be sent vertically to the tin furnace (size according to SOP requirements). When the core wire is in place, the wire must be taken out immediately.

6. Terminal crimping
Use a small crimping machine to crimp the cut wires onto the terminals. Sometimes multiple wires can be crimped to one terminal.

7. Packaging
Separate the crimped wires according to the requirements of the disassembly process, that is, insert the terminals into the sheath.

8. Assembly
Assemble the subassembly on the drawing board according to the circuit direction (bundled with tape or drawstring into a bundle, which is the wiring harness).

9. Electrical testing
Use a standard wire testing machine to test the voltage, impedance, short circuit and other properties of the wire.

10. Appearance inspection
Use the naked eye to check whether some appearance parts are up to standard, whether accessories are missing, etc.

11. Packaging
Arrange the wires neatly and package them (500PCS/box) 50PCS/tie, 5 ties/bag, 2 bags/box. When the box is full, use a carton sealing machine to seal and label the box.