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.
Release time:
2022-11-15
The manufacturing process of automotive wire harnesses generally consists of 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 minor errors can impact production efficiency. Therefore, most wire-harness manufacturers today use fully automated wire-stripping equipment. In the crimping process, crimping parameters and the required crimping dies must be determined based on the customer’s crimping standards and terminal types. Since crimping quality directly influences electrical performance, this stage is a critical work station. A dedicated crimping operation manual should specify special requirement characteristics, and random inspections of crimping quality should be conducted online according to established regulations, with the formation of a prescribed control chart for characteristic monitoring. As for the pre-assembly process, the primary task is to assemble the exposed wires and crimped wires entering and exiting the plastic components into KITs according to the process instructions. This approach helps reduce investment costs for production line equipment, simplify assembly operations, and decrease the number of assembly personnel required. For simpler automotive wire harnesses, pre-assembly can often be eliminated altogether; however, for more complex harnesses, it is common practice to set up a dedicated pre-assembly station first. Next comes the final assembly stage, during which the pre-assembled wire harnesses are systematically arranged on the final assembly fixture according to the process instructions. This stage also involves organizing the wire harnesses, applying cable ties, bundling and combing the cables, and installing all necessary accessories such as rubber parts. The final step is the post-assembly process, which includes mounting brackets, conducting electrical tests, performing full-size testing, and then securing and packaging the finished product.
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