An electronic wiring harness comprises wires, terminals, plastic parts, and other components. In the electronics industry, an ‘electronic wiring harness’ typically refers to a low-voltage wire assembly that facilitates transmission between two isolated electronic circuits. It is an indispensable product in electronic equipment to realize various functions.
Complex electronic wiring harnesses require components such as tapes, cable ties, sleeves, sheaths, and labels need to be used. For example, automotive electronic wiring harnesses are more complicated. They are different from standard electronic wiring harnesses. They typically consist of multi-core soft wires; some cables are as thin as a hair, with several or even dozens of delicate copper wires encased in insulating tubes that are smooth and resistant to breakage.
Electronic wiring harnesses are commonly used for the internal assembly of electronic appliances, offering greater efficiency and flexibility compared to traditional wiring.
The wiring harness processing and production involve the following steps:
Cutting wire – peeling – brushing wire – twisting wire -tinning – terminal crimping – sub-assembly – assembly – electrical inspection – appearance inspection- packaging.
1. Cut the line
Use automatic wire cutting equipment to cut the wires to the required size, arrange the cut wires neatly (50 pieces per tie), place them in the designated position, and affix the logo.
2. Peel off the skin
Install the appropriate blade based on the wire specification. Adjust the peeling stroke, thread clamping, and trimming according to the process index. Set the size adjustment plate to the desired peeling length. Position the wire centrally in the blade, press its end against the size adjustment plate, and activate the foot pedal to peel.
3. Brush the line
Upon powering on, the electric copper brush rotates clockwise. Following the SOP method, the exposed oblique cladding at both ends is separated from the core wire, and the separated cladding (i.e., the ground wire) is twisted and straightened.
4. Twist the wire
Ensure the twisting clip is complete and the rotational force is even. Insert all brushed copper wires into the twisting clip for twisting, ensuring the copper wire is clamped at the central bottom position
5. Dipping tin
Set the tin furnace to the temperature specified in the SOP (300±20℃). Arrange the wires, separate and align the core conductors, apply flux to the core conductors, and insert the core wires vertically into the tin furnace as per SOP requirements. Once tinned, promptly remove the wires.
6. Terminal crimping
Use a small crimping machine to attach the cut wire to the terminal; in some cases, multiple cables can be crimped onto a single terminal.
7. Packing
Package the crimped wires are sub-packaged according to the sub-assembly process requirements. That is, the terminals insert into the sheath.
8. Assembly
Assemble the sub-assembled sub-assemblies according to the circuit directly on the drawing board (tape or draw straps bundle into bundles, that is, wire harnesses).
Use a standard wire testing machine to test the wire’s voltage resistance, impedance, short circuit, and other properties. Here you can consider working with the ATX-3000S harness tester.
10. Appearance inspection
Use the naked eye to check whether some appearance parts meet the standards, whether there are missing accessories, etc.
11. Packaging
Arrange the wires neatly and pack according to the method shown in the figure (500PCS/box) 50PCS/bar, 5 bars/bag, and two bags/carton; when the package is complete, use a carton sealer to seal and label the box.