Overmolded Connector Harness Assembly Process and Requirements

Overmolded connection harness is a collection of strings of wires and cables used to transmit power, information or operating signals. Overmolded Wire harness binding materials include clips, cable ties, sleeves, electrical tape, or a combination of these materials. In this article, the Overmolded wire harness engineer mainly talks about the wire harness assembly process and requirements.

Assembly process of connection harness
1. When making the wire harness sub-material number, the cutting line size must be determined according to the positioning plate.
In the current wire harness assembly process, the size of the sub-material number can often be met, but the size of the positioning plate cannot be met, resulting in a lot of unnecessary waste. Sub-material numbers also require electrical testing and full inspection.

Mini-Fit Overmolded Cable Assemblies

Design Overmolded connection harness structure diagram

2. Wiring harness routing.
① Lay out each sub-material number on the positioning plate according to the requirements of the drawing.
② When wiring, first place it area by area. After placing the sub-material numbers in a single area, place the sub-material numbers across areas.
③ For cross-region sub-material numbers, simple ones should be placed first, and then complex ones.

3. Insert the connector PIN (some TERs without PIN must be inserted into the corresponding connector first).
Wire tying (the tying position is according to the positioning plate, and the starting point of the tying is generally the starting point of the double line in the positioning plate).

The wiring harness wiring structure of the control box in a certain equipment

4. Electrical test.
① Due to the complexity of the assembly line, the test data must be strictly checked.
② Testing can only be carried out after confirmation by PE & QE.

5. Full inspection.
① Check whether the terminal and CONN are within the tolerance zone.
② Check whether the wire binding ring is even.
③ Check whether the assembly method of parts is correct.

6. Warehouse the wiring harness sub-material number.
The sub-material number must be inspected and PASSed by OQC before subsequent actions can be taken.

Assembly process requirements:
1. After the wire harness is processed and assembled, all wire harnesses must be parallel and cannot move. However, the cable ties or zip ties must not snag the wires.
2. When inserting PIN or welding, the core wires cannot be twisted together, but they cannot be too tight.
3. When wiring, the terminals, HOUSING, D-SUB, IDC, and CONN of each sub-material number must match the markings on the positioning plate.
4. The wires of each sub-material number must be arranged according to the route on the positioning board.
5. When tying the line, the rope should move vertically from the bottom of the tying ring.
6. The cable tie should be tightened and the tail should not exceed 1mm.
7. When tying the line, the distance between the two tying rings should be about 25mm, and each rope should be tied to the end with a tail of about 10mm.
8. Tie a dead knot at the beginning and end of each rope.
9. When tying the wire, do not loop or wrap the rope. Do not jam the connector on the locating pegs and pull the cord hard. The thread end of the rope should be fixed on the locating nail and then tied. Otherwise, the terminal may easily break the core wire or the terminal may fall off.

Assembly quality standards:
After the wire harness is assembled into a finished product, the conductivity rate of the wire harness line must be tested to ensure that the conductivity rate is 100% and there are no short circuits or wrong circuits. At the same time, it must also meet the quality standards required by wire harness customers, and provide a safety and quality guarantee certificate when packaging.
Every step of the wire harness assembly and testing process strives to be meticulous, strive for excellence, and standardize operating requirements in accordance with the ISO 9001:2015 quality management system.