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2022.11.15
Process production steps for automotive wire harnesses
The manufacturing process of automotive wire harnesses can generally be divided into four steps: first, the wire stripping and crimping process; second, the pre-assembly process; third, the final assembly process; and finally, the post-assembly and finishing process. The wire-stripping process requires meticulousness and rigor—its accuracy directly affects the overall production schedule, and even a slight error can impact production efficiency. Therefore, most wire-harness manufacturers today use fully automated wire-stripping equipment. As for the crimping process, crimping parameters and the required crimping dies must be determined based on the customer’s crimping standards and the type of terminal being used.
Fields and Applications of Each Harness Industry
Whether it’s traditional consumer electronics, home appliances, or emerging technologies such as new-energy vehicles, foldable-screen phones, 5G, or the Internet of Things, what all these aim to achieve is the connectivity among devices themselves, between devices and people, and between people and data. All of this hinges on wiring harnesses. As 5G, new-energy vehicles, and smart-device interconnectivity continue to develop rapidly, the wiring-harness industry is facing new challenges. At the same time, how to improve wiring-harness manufacturing processes to meet evolving market demands has become an urgent issue that the industry must address. The main types of wiring harnesses produced across various industries fall into four categories: medical wiring harnesses, automotive wiring harnesses, and industrial control wiring harnesses.
Some knowledge about automotive wiring harnesses
The automotive wiring harness is the backbone of a vehicle’s electrical system; without it, there would be no vehicle circuitry at all. A wiring harness consists of contact terminals (connectors) made from stamped copper components that are crimped onto wires and cables, then encased in a molded insulating material or enclosed within a metal housing. These harnesses are bundled together to form a complete assembly that connects various electrical circuits. The wiring harness industry chain encompasses wire and cable products, connectors, processing equipment, harness manufacturing, and downstream application industries. Wiring harnesses have extremely wide-ranging applications, being used in automobiles, household appliances, computers and communication devices, as well as a variety of electronic instruments and meters. The body wiring harness connects the entire vehicle body and generally has an H-shaped configuration.
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