The processing flow of a wire harness

The processing flow of a wire harness encompasses the following sequential steps: incoming material inspection and storage, wire cutting, crimping, sub-assembly, assembly, inspection, and packaging.

1. Incoming Material Inspection and Storage

For a wire harness, incoming material inspection and storage is the crucial process of thoroughly examining the raw materials earmarked for production and then storing them appropriately. This ensures that these materials are of high - quality and ready for use when required in the manufacturing process, thereby laying a solid foundation for the subsequent production steps.

2. Wire Cutting

Wire cutting involves the meticulous operations of cutting wire conductors of various specifications, stripping their ends, and bundling them. These operations are carried out in strict accordance with the process documents, which are based on the design drawings. This step is essential for preparing the wires in the correct lengths and with the proper end - treatments for further processing.

3. Crimping Process

The crimping process is all about firmly joining the wire and the terminal together. Through a specific crimping mechanism, a reliable mechanical and electrical connection is established between the two components, which is vital for ensuring the integrity and functionality of the wire harness.

4. Sub-assembly Process

Sub-assembly, sometimes also referred to as pre-assembly, is the process of combining semi-finished products obtained after wire cutting or crimping with components such as protective sheaths, pipes, and rubber parts. This combination results in the creation of new semi-finished products, which are more complex and closer to the final product in terms of structure.

5. Assembly Process

Assembly, often called final assembly, is the stage where the semi-finished products from wire cutting or crimping, along with those from pre-assembly, are integrated with other materials. This comprehensive combination gives rise to the complete and fully - functional wire harness products, which are now ready for the final inspection.

6. Inspection Process

The inspection procedures are comprehensive and crucial for ensuring product quality. They mainly include an appearance inspection to check for any visible defects, an inspection of installation accessories to ensure their proper fit and functionality, a functional inspection to verify that the wire harness performs as expected, a 100% electrical inspection to guarantee electrical integrity, and imaging inspection for a more in-depth visual examination of internal components if necessary.

7. Packaging Process

The packaging process is the last step in the wire harness production line. It involves carefully arranging the wires in an orderly manner and then packing them into boxes. This not only protects the wire harnesses during transportation and storage but also makes them easier to handle and distribute.