The assembly process of the electronic wiring harness must be performed with great care, as any defect in the production assembly process can trigger the failure of the product as a whole, resulting in unexpected accidents. Although manufacturers know the seriousness, there are some common mistakes made when producing assembled wiring harnesses. The following is a list of 6 common mistakes in the production and assembly of electronic wiring harnesses.
1. Prepare the wires
Preparing the wires must be performed with care and precision, as it determines the overall efficiency and performance of the assembly, and many manufacturers go wrong at this first stage, choosing the wrong wires, which are cut and stripped at the ends.
2. Not following assembly drawings
Failure to follow the assembly drawing can lead to many problems when connecting the wires in the chassis. Harness manufacturers often connect the wires incorrectly, which makes the wire assembly fail, which in turn causes the entire system to fail. The assembly drawing must be strictly followed to avoid such mistake.
3. Defects in crimping
The crimping process involves terminating the wire harness into the wire harness, which is the most critical step in a wire harness assembly and can result in an open or short circuit if not performed properly. If many manufacturers do this haphazardly, it will cause the product to fail sexually.
4. Incorrect soldering
Improper Soldering This is another major area where manufacturers make mistakes. Improper soldering of wires and terminals can cause thermal damage. When doing this, use the correct soldering equipment and the correct soldering temperature.
5. Missing wires and using the wrong hardware
To meet project schedules, some wire harness manufacturers may tend to ignore wires that are critical in assembly. This can lead to failure of the wiring harness assembly, in addition, the manufacturer may use the wrong hardware, including brackets, clamps, washers or screws to assemble the wiring harness.
6. Incorrect wire connections
The final step in the harness assembly process is to wrap the wires with plastic straps, which sometimes the harness manufacturer will wrap so tightly that it damages the wires. On the other hand, if it's loose, there's a chance that the bundle won't be held properly, so the manufacturer has to make sure that the tie is fastened the correct way around the wire.
If the above errors can be avoided, taking into account other assembly specifications, the wire harness manufacturer can assemble the wire harness according to the customer's requirements, and a double inspection process can help eliminate the above defects and produce a high quality wire harness.
