Wire Harness Assembly Process

Publish:

2025-01-02 11:30

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1.Wire Preparation   

Wires are first cut to the required lengths using either manual cutters or automated wire cutting machines. The ends of the wires are then stripped to expose the metal conductor.

 

2. Crimping Terminals to Wires

Crimp terminals are attached to the ends of wires, which will assist in connecting the wires to their associated boards down the line. Crimping is usually achieved with a crimping tool or machine to ensure a secure and reliable connection.

 

3. Inserting Wires into Connectors

Wires with crimped terminals are inserted into their respective connectors. This may require specific tools or machines, depending on the connector type.

 

4. Assembly of the Backbone

The main cables are laid out and bundled together to form the backbone of the wire harness. This step might involve routing wires through protective sleeves or conduits.

5. Branching Off

Secondary wires or branches are connected to the “main backbone” at various points, according to the wiring diagram or schematic.

 

6. Application of Protective Coverings

Protective materials such as heat shrink tubing, specialized tubing, or tapes are applied to protect the wires and connectors from environmental hazards.

7. Testing Each Connection

Electrical tests are conducted to ensure each wire is correctly connected, and there are no shorts, opens, or miswirings. Continuity testers or multimeters are used here.

8. Final Assembly and Securing

The entire harness is assembled according to the layout, with all branches and connectors in place. Cable ties, clamps, or tapes are used to secure the harness structure.

9.Quality Inspection

The completed harness is inspected visually and through additional tests to ensure it meets all specifications and quality standards. Advanced testing may include dynamic stress testing to simulate environmental conditions (temperature cycling, vibration, moisture exposure) and ensure the harness’s longevity and reliability under operational stresses.

 

In today's world of automated manufacturing, it is worth noting that the wiring harness assembly process still continues to rely on manual labor. Although there is a degree of automation potential, the complex nature of assembling wiring harnesses and cable assemblies requires manual operation. Making a wire harness involves many detailed and time-consuming tasks, and in many cases, manual assembly is not only necessary, but also more cost-effective. In addition, the need for manual production in the creation of wiring harnesses and cable assemblies is the result of their inherent customization requirements. Wiring harnesses are highly specialized components, tailored to suit specific applications and large systems, and therefore require manual craftsmanship in their assembly.

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