Assembly process of automotive wire harness welding

1. The starter wire harness and starter wire harness are maintained through glass fiber tubes

2. When the battery compartment and the starter are on the same side of the frame, the starter wire beam is fixed to the frame girder with a fixed support; If it is different, it is necessary to transition from the frame beam (or welded round steel) to the other side and then fix it along the frame girder. 

3. The generator wiring harness is generally different according to the position of the battery compartment and the generator: the battery compartment and the generator are on the same side of the starter when the wiring harness is usually fixed on the longitudinal beam of the frame with a support; When the battery compartment and the generator are on different sides of the starter, one is that the wire harness is fixed along the longitudinal beam and then overpasses the generator from the tail of the starter through the support of the intercooler, and the other is that the wire harness transitions from the frame beam (or welded round steel) to the other side and is laid along the longitudinal beam or the intercooler support. In individual cases, fixed supports of different shapes and sizes can be applied to lay on the initiator. 

The generator harness shall not be tied together with the iron harness.

Quality request:

1. The request harness should have an active margin (30 ~ 50)mm. 

2. The maintenance of the glass fiber tube is complete, and the part of the glass fiber tube exposed at the end of the wire harness does not exceed 50mm.

3. Wiring harness allowance reservation request: First make the wiring harness end and the motor terminal try to connect, and then increase the wiring harness activity allowance (30 ~ 50)mm on this base after certain length. 

4. In order to ensure the rationality of the wiring harness layout, the convenience of maintenance, and the fixed divergence, different types of fixed brackets can be properly installed: straight plate type, L-type, plated, galvanized, etc., but the divergence of the consumer batch must be ensured. 

5. The wiring harness layout is uniform, fixed and firm, no shaking overhang, no intervention force, no friction damage.

hauling

Process content:

(1) When mounting the hauling chassis, the retainer should be removed when the trailer hook has a retainer through the hole, so that the retainer is not damaged, and then the retainer is maintained on the line at the hoisting station.

Quality request:

The bearing chassis shall not damage the rubber ring through the wire hole or the bellows.

When the loading workshop is running, the longer thread should be placed on the body of the car.

Quality request:

Do not drag the wiring harness on the ground or step on it.

Check the connector before wiring harness connector.

Process content:

1. Before inserting the cable harness connector, check the connector in good condition. Check the following items: Whether the positioning block of the waterproof connector is intact, whether the unused hole is plugged with a special waterproof plug, whether the pin is bent and deformed, whether the waterproof plug on the line is correctly inserted into the sheath of the connector (after insertion, the waterproof plug should be well fitted with the sheath, without distortion and preventing water from entering the connector), and whether the sheath lock buckle is damaged. 

2. Stop checking common non-waterproof connectors according to waterproof connectors. All connectors at the engine must be waterproof.

Quality request:

After inserting the connector, check whether the pin exits from the sheath, whether the connector can vibrate, and whether the wiring harness can be tied too tightly (mainly at the junction with the lamp, solenoid valve, etc.). If the connector is found to have vibration, Should the connector stop fixing (the connector vibration for a long time may form the connector's scattered) about the screw mounting connector must be rotated in place (when in place, you can hear the loud sound), otherwise there will be poor wiring harness contact after a long time of operation.

Wire harness cutting wiring standard

Process content:

1. Mainly for the operation of the sensor harness, the main harness must not show the phenomenon of cutting and rewiring.

2. When the wiring harness is too short and needs to be rewired, the cutting harness shall not be cut in parallel, and the difference between the two wiring harnesses shall be about 30mm. The conductor shall not be broken when crimped, and the cross section of the contact shall meet the quality requirements. After wiring, wrap the insulation tape. The insulation tape should be wrapped completely, the tape should be wrapped with appropriate thickness, safe, secure and beautiful.

3. If you need to crimp the terminal again after the connectors fail to be inserted, crimp the terminal on the conductor and the insulation layer respectively. The conductor should not be broken and the insulation layer should not be pressed into the crimp part of the conductor. The cross section between the crimping terminal and the wire should meet the quality requirements. The connection between the terminal and the wire should be strong, and should not be damaged and detached under the tension of the rules, and the tension value should be less than the rules of Schedule 1. 

4. When wiring, the wire diameter and color of the selected wire and the docking wire should be unified. If it is not agreed under special conditions, it is necessary to ensure that the wiring of the same model car is different in the same position.

Process parameters:

1. The difference between wiring harness joints is about 30mm. 

2. Branch length should not be less than 30mm. 

3. The interval between the contact and the branch point should not be less than 20mm. 

4. If an insulation tube is installed at the connection between the cable and the terminal, the length of the insulation tube must not be less than 20mm.