Production Process of E/E system & E-PLUS Wiring Harness

With the continuous improvement of people’s requirements for comfort, economy and safety, the types of electronic products on cars are also increasing. The failure rate of more and more complex wiring harnesses in automobiles has also increased accordingly. This requires improvement in performance such as reliability and durability of the wiring harness. Many people are more interested in the process and production of automotive wiring harnesses. Here is a brief description of the knowledge of automotive E/E system & E-PLUS wiring harness technology and production. You only need to spend a few minutes reading to get the general idea.

After the two-dimensional product drawings of the automotive wiring harness come out, the production process of the wiring harness must be arranged. Craftsmanship serves production, and the two are inseparable. Therefore, the author combines the production and technology of automobile wiring harness to analyze together.
The first station in wire harness production is the wire cutting process. The accuracy of the cutting line process is directly related to the entire production schedule. Once an error occurs, especially if the opening size is too short, it will lead to rework of all stations, which will waste time and effort and affect production efficiency. Therefore, in the preparation of the cutting process, it is necessary to reasonably determine the cutting line size and stripping size of the wire according to the requirements of the drawings.
The second station after cutting the line is the crimping process. Determine the crimping parameters according to the terminal type required by the drawings, and make crimping operation instructions. For those with special requirements, it is necessary to indicate on the process documents and train the operators. For example: Some wires need to pass through the sheath before they can be crimped. It requires wire to be pre-assembled and returned from the pre-assembly station for crimping. There are also special crimping tools used for piercing crimping. This crimping method has good electrical contact performance.
The next step is the pre-installation process. First of all, the pre-installation process operation manual must be compiled. In order to improve the efficiency of final assembly, pre-installation stations must be set up for complex wiring harnesses. Whether the pre-assembly process is reasonable or not directly affects the efficiency of the general assembly and also reflects the technical level of a craftsman. If there are too few pre-assembled parts or the assembly wire path is unreasonable, it will increase the workload of the assembly personnel and slow down the speed of the assembly line. Therefore, craftsmen should always stay on site and constantly summarize.