What Is the PCB Wire Harness Assembly?
A wire harness assembly is sometimes called a cable or wiring loom. It arranges multiple groups of wires and/or cables into a single unit to protect and organize the various connected terminals and connectors. The shape or layout of these terminals and connectors routes the connectors to the various connection points of the assembly.
ZF Electronics has decades of experience in PCB assembly manufacturing, custom wire harness assembly manufacturing, and sub-assemblies for our commercial and industrial partners.
Wire Harness Assembly Board Design
The harness design is highly customizable because the harness is usually designed for a specific application. ZF Electronics accept individualized customer service. Please send us your detailed requirements if you are in need of wire harness assembly boards.
Wire Harness Assembly Process
The first station of the Wire Harness Assembly is the opening process. The accuracy of the opening process is directly related to the whole production progress. Once an error occurs, especially the opening size is too short, it will lead to rework of all stations, time-consuming and laborious, and affect the production efficiency. Therefore, when preparing the wire opening process, we must reasonably determine the wire opening size and stripping size according to the requirements of the drawing.
The second station of making the wire harness assembly board is the crimping process. The crimping parameters are determined according to the terminal type required by the drawing, and the crimping operation instructions are made. If there are special requirements, it is necessary to indicate them on the process documents and train the operators. For example, some wires need to pass through the sheath before crimping. It needs to pre-assemble the wires first, and then return from the pre-assembly station before crimping; In addition, special crimping tools are used for puncture crimping, which has good electrical contact performance.
The third station of manufacturing the harness assembly board is the pre-assembly process. First, prepare the pre-assembly process operation manual. In order to improve the general assembly efficiency, the pre-assembly station should be set for complex wire harnesses. The rationality of the pre-assembly process directly affects the efficiency of the general assembly and reflects the technical level of process personnel. If the pre-assembly part is less assembled or the assembly wire path is unreasonable, it will increase the workload of the general assembly personnel and slow down the speed of the assembly line. Therefore, the process personnel should often stay on the site to summarize.
The final step to make the wire harness assembly board is the final assembly process. Be able to compile the assembly platen designed by the product development department, design the specifications and dimensions of tooling equipment and material box, and paste the numbers of all assembly sheaths and accessories on the material box to improve the assembly efficiency. Prepare the assembly contents and requirements of each station, balance the whole assembly station, and prevent the situation that the workload is too large and the speed of the whole assembly line is reduced. To achieve station balance, the process personnel must be familiar with each operation, calculate the working hours on-site, and adjust the assembly process at any time.
Advantages of Wire Harness Assembly
Protecting the Project from Direct Damage
Protection Against Compromised Wires
Preventing Direct Physical Damage
Preventing Damage from Heat
Improving the Flow of Air Within the Chassis