Packing
Sub-assembly is applied to batch wiring harness production. This process seems trivial at first glance, but for mass production and C, its role can be underestimated. In traditional production, the concept of sub-assembly is small in wire harness production. Route the wires to the nail board one by one according to the drawing, wrap the tape after the wire is laid, and cut the 4 wire harnesses to align the wire heads. It takes a few meters to waste as many as several tens of meters of wires. Dismantling, the wires of the crimped end r flowing out from the offline process can be inserted into the connector according to the classification of technical documents, and then flow into the wiring process as a whole (product identification through the process flow sheet) is suitable for mass production, It can make the operator form a habitual action, minimize the possibility of the end r being inserted into the wrong hole position, and provide a guarantee for the quality of the subsequent process.
5. Wiring
Traditional wiring operators have to nail the board according to the drawings, and the wires are easy to loose and dislocate during wiring. Nowadays, wiring harness companies convert the drawings into 1:1 wiring diagrams, that is, the physical drawing of the wiring harness made according to the actual size of the standard, and then 1.1 wiring harnesses. The wiring board is generally used with three specifications of 1.8m*0.9m, 2.4m*0.9m and 3.6m*0.9m, and the wiring harness can be arbitrarily selected or superimposed from the three specifications. Combining 4 branch points to fix the wire forks, the 4 wire ends use wire forks and plastic clips to fix the wires, and the small is the traditional winding nail fixing The advantages of the new technology are accurate size, saving wires, reducing the work intensity of operators, and improving Productivity.
When wiring, the operator first needs to check whether each wire fork of the wiring board is installed firmly and the angle is correct; the wiring sequence is generally given priority to the ground wire (with the most parallel points), and then arranges the sub-assembly wiring harness and other wires. To ensure that the wiring harness is neat and straight, after the wiring is completed, the mountain wiring personnel use black insulating tape to perform preliminary wrapping for fixing, and the wrapping is required to be beautiful, firm, and free of bulging. Then it flows into the wrapping process.
6. Bandaging
When the traditional technology is used for dressing, the effect of the small bandage operator is small, and the inspector is also very good at judging whether it is qualified or not. We can only judge by experience. When the product is sent for inspection, it is often that the ICI bellows with the same diameter is wrapped with the same branch, resulting in small thickness and small uniformity. , product quality is affected.
Today, the operator refers to the process documents and the drawings of the standard corrugated pipe type. The operator must first check that the wiring harness has no errors, and then select and cut the corrugated pipe of the appropriate size according to the requirements of the drawings, and then move from the connector end to the The main ten directions are wrapped, and finally the open corrugated pipe is tightly wrapped with insulating tape to ensure a smooth appearance. The processing of the branch point also requires dense wrapping with insulating tape, and there is no wire exposed phenomenon. And make sure the exposed wires are neat.
7. Secondary crimping
One-time crimping refers to the supplementary crimping of the remaining un-crimped terminals by the operator using a semi-automatic crimping machine. One-time crimping requires a higher ability of the operator to identify the terminal. The first crimping in 4 days requires a first-piece tensile test. The semi-automatic crimping machine needs to be cleaned before leaving get off work.
The semi-automatic crimping machine is distinguished according to the end r mold of Xiaotong. The Xiaotong mold is made by the crimping machine manufacturer according to the Xiaotong terminal. During the actual operation, the operator selects the appropriate crimping according to the guidance of technical documents and production experience. machine for production.
After the terminal crimping is completed, the operator should check the appearance of the terminal r after crimping, if it is small, it needs to be trimmed.
8. Plugins
The external quality feedback rate of the plug-in process is very high, and the problems are mainly concentrated in three aspects: (1) the use of the connector model is wrong; (2) the terminal insertion sequence is wrong; (3) the terminals are not plugged firmly; (4) blind Auxiliary materials such as plugs or fixing pieces are missing
In order to solve this problem, the wiring harness company has formulated a work instruction to provide detailed guidance for the 4 production steps of the operator, implement an assessment system for the plug-in process personnel, strictly refer to the technical documents for operation, and enforce the consciousness of the personnel. In order to strengthen the docking of operators For the identification of the plug-in, we propose the concept of mirror image for the product drawing, that is, it is defined by the outlet end (connected with the connector) or the incoming end (the direction in which the terminal is inserted into the connector), and all the connectors on the drawing are drawn as one-dimensional. The connectors are flat and flat, so that everyone reduces the possibility of wrong insertion sequence.
