In modern industrial production, the quality and reliability of the
Wiring Harness as an important component of electrical connection is directly related to the operating efficiency and safety of the entire equipment. However, in the process of processing the wiring harness, various problems are often encountered, which not only affect production efficiency, but also may bring safety hazards. This article will explore the causes of wiring harness processing problems in depth and introduce corresponding detection methods in order to improve the quality of wiring harness processing.
Causes of wiring harness processing problems
1. Raw material problems: The first step in wiring harness processing is the selection and use of raw materials. If the raw materials have impurities, aging or mechanical properties that do not meet the standards, it will directly affect the quality of the finished product of the wiring harness. For example, damp aluminum rods and impurities in wires will cause adverse phenomena during processing.
2. Unreasonable design: The design of the wiring harness is directly related to its use effect and life. Unreasonable design, such as improper connector design and insufficient thickness of the copper-tin layer of the terminal, will lead to problems such as difficulty in plugging and unplugging, poor signal or signal loss.
3. Lax process control: During processing, the strictness of process control directly affects the quality of the wiring harness. For example, the phenomenon of false soldering, false soldering, and too long tin tip during welding is often caused by the operator's lack of expertise in soldering or defects in raw materials.
4. Human operation errors: During the installation and maintenance process, improper human operation is also an important cause of wiring harness problems. For example, unreasonable installation position of the wiring harness, wrong wiring, damage to the wiring harness components during maintenance, etc., will cause damage and failure of the wiring harness.
5. Natural aging and environmental factors: As time goes by, the natural aging of the wiring harness and the influence of environmental factors (such as high temperature, low temperature, humidity, corrosive gas, etc.) will also cause the insulation layer of the wiring harness to crack and the mechanical strength to decrease, thereby causing short circuits, open circuits and other faults.
Detection methods for processing wiring harnesses
In order to ensure the quality and reliability of the wiring harness, a series of detection methods need to be adopted to discover and solve problems.
1. Appearance inspection: Visually inspect the appearance of the wiring harness to check for surface defects such as scratches, deformation, damage, oxidation, and whether the connectors are firm. This is the first step to discover wiring harness problems.
2. Conductivity test: Use a conductivity tester or multimeter to test the conductivity of the wiring harness and confirm whether the resistance is within the specified range. This is an important means to ensure the electrical performance of the wiring harness.
3. Insulation test: Use an insulation tester to detect the insulation performance of the wiring harness, confirm whether the insulation resistance meets the requirements, and avoid leakage or short circuit.
4. Continuity test: The wiring harness continuity test is the most basic test item, which is used to ensure the quality and reliability of the wiring harness. The continuity tester can detect unqualified products such as open circuit, short circuit, dislocation, etc. in the wiring harness, so as to rework.
5. Environmental adaptability test: Expose the wiring harness to different environments, such as high temperature, low temperature, humidity, corrosive gas, etc., to detect its working performance and tolerance in different environments. This helps to evaluate the environmental adaptability of the wiring harness.
6. Durability test: Test the durability and reliability of the wiring harness by simulating the service life of the wiring harness, such as frequent bending, twisting, plugging and unplugging operations. This helps to predict the performance of the wiring harness in actual use.
7. Vibration test: Fix the wiring harness on the vibration test equipment for vibration test to simulate the vibration conditions in the actual working environment and detect its resistance to vibration. This helps to evaluate the stability of the wiring harness in a complex working environment.
Sejow can provide OEM/ODM wiring harness ，Cnc Machining Parts based on your requirements. Wiring harness, also known as Cable Harness, CNC machining parts are assembly of Cnc Milling Service which transmit signals or electrical power. In the future, Sejow will continue to uphold the business philosophy of "integrity, responsibility, and innovation", provide customers with better products and services, and work together to create a better tomorrow. Consultation hotline: 0755-29426119.
Sejow (Shenzhen) Industrial Co., Ltd.
