​How to manufacture a new energy vehicle wiring harness?

The ideal outcome of the design of a new energy vehicle wiring harness is to be able to use short wires and suitable wire cross-sections to ensure that all automotive electrical and electronic equipment can work properly. Therefore, there are strict requirements for wire material, quality, and conductivity. The manufacturing process of wire harnesses includes pre-assembly, online, sheath assembly, tape wrapping, tube installation, tube wrapping, positioning clip assembly, wire drop, electrical testing, full inspection, and packaging into storage. Several of these steps are highlighted below.

Here is the content:

Pre-assembly

Plugging terminal

Assembling sheath

Pre-assembly

Pre-assembly is the process of putting plugs, plug sticks, positioning clips, etc. into the connector before going online. The operation method is to first install the positioning clip directly into the connector slot. Usually, a crisp sound will be made when it is in place. At the same time, check the positioning clip for damage. The plug or plug stick is then installed directly into the hole at the location required by the visual aid. The plug is squeezed into place with the plugging tool. Finally, the pre-assembled semi-finished product is loaded into the designated material box.

Plugging terminal

An important step in making a new energy vehicle wiring harness is inserting the terminal, which is the process of inserting the branch through the closure tube, sheath, etc., and then into the connector. The purpose is to ensure that the terminal is in place and locked intact in the connector. The operation method is: first take the connector and check whether the locking tab is open. Next, observe whether the connector is waterproof to determine whether the terminal has a sealing plug. Take the branch circuit and also check whether the terminals and wires are damaged. Observe the locking mechanism inside the connector hole and the locking part of the terminal to decide the direction of inserting the terminal. Finally, terminal insertion is performed, and the same terminals in the same direction of the connector ensure the same brush direction.

Assembling sheath

Assembling the sheath is the act of passing the branch through the sheath and fixing it to the new energy vehicle wiring harness. The operation is: first, the branch is passed through the sheath and then inserted into the connector. Then the sheath is threaded with a spreader. Because the sheath is sometimes installed with a lubricant called a release agent, more tape wrapping is required to secure the sheath. When it comes to wire harnesses that need to be glued, the sheath must be installed in place. When the sheath is expanded and installed, it is necessary to check whether the sheath is intact. When installing the sheath, care needs to be taken not to damage the terminals. After the branch circuit passes through the sheath, make sure to check whether the terminals are good or bad.

With the development of automotive electronics technology, the new energy vehicle wiring harness has also been further developed. It is the responsibility of each manufacturer to produce a new energy vehicle wiring harness that meets the standards to ensure the interests of consumers and the healthy development of the market. We have conducted several tests on this product before leaving the factory, and the quality pass rate is guaranteed. If you are in the wiring harness business, you can consider our cost-effective products.