HOW TO DEAL WITH TERMINAL HARNESS POOR CONTACT IN THE PROCESSING?

Insulator surface or internal management of metal excess. Surface dust. Pollution such as solder; organic binding material precipitation and harmful gases through the adsorption film and surface water film to form an ionic conductive channel. Hygroscopicity. The aging of the insulating structure materials, etc., can directly lead to the system short circuit. Leakage. Breakdown. Insulation resistance and other poor insulation phenomena. If the connection end of the poor contact how to do? 

1.Orientation test. 

At present, terminal manufacturers usually do not test the product, and the user often need to carry out the flip test. It is recommended that some key models of the manufacturer's products should be improved to point conduction test. 

2. instant detection. 

Some terminal connections are used for dynamic vibration control environment. Experimental studies have shown that the static contact resistance test alone is qualified, it can not guarantee that the enterprise in a dynamic development of the environment using contact reliability. This is because, typically, connectors that do not have qualified terminal contact resistance are subjected to effective vibration. Shock and other simulated technical environmental factors test, there will still be instantaneous power failure, therefore, for certain terminals with high reliability requirements, dynamic vibration testing can be carried out to ensure contact reliability. 

3. single-hole separation force test. 

Centrifugal force is inserted into the state, the separation force of the contact part from static to movement, to characterize the contact state of the needle and jack. Experimental results show that the single-hole separation force is too small, under the action of vibration and shock load, the signal will instantly rupture. Detecting contact reliability is more effective than the single-hole separation force method. Inspection found that the single-hole separation force exceeds the poor jack, the contact resistance is often still qualified. In order to achieve this goal, wire harness processing manufacturers in addition to the development of a stable and reliable new generation of flexible plug-in contacts, for important models, wire harness processing manufacturers can not use multi-point force gauge for multi-point testing, the finished product should be a point by point single-hole separation force check, to prevent the individual jacks loose caused by signal transients.

Automotive wire harness machining has the following requirements: 

1. Opening Process. The accuracy of the opening process is directly related to the overall production schedule. Once an error occurs, especially if the opening dimensions are short, it will lead to rework of all stations, which will take time and effort to affect productivity. Therefore, in preparation for the opening process, it is important to rationalize the opening size and dimensions of the wire in accordance with the attached diagram. 

2. Crimping process. Determine the crimping parameters according to the terminal types required by the drawings and produce a crimping operation manual. For special requirements, indicate and train operators in the process documentation. For example, some wires need to pass through the sheath before crimping. It needs to be pre-assembled and returned from the pre-installation station and then crimped. In addition, penetrating crimps use special crimping tools. The crimping method has good electrical contact characteristics. 

3. Pre-installation process. First, a pre-installation process operation manual should be compiled. In order to improve the assembly efficiency, complex wiring harnesses must be equipped with a pre-installation station. The rationality of the pre-installation process directly affects the efficiency of the overall assembly and reflects the skill level of the craftsman. If the pre-installation portion of the component is too small or the assembly is not wired properly, the workload of the total assembly crew will increase and the speed of the assembly line will be slowed down. Therefore, process personnel should remain on site frequently to summarize the process. 

4. Assembly process. It can be programmed according to the assembly board of the product development department, design tools and equipment, material box size, and connect all component sheaths and accessory numbers to the material box to improve assembly efficiency. Compiles the assembly content and requirements for each workstation and balances the entire assembly station to prevent overloading the workload and slowing down the entire assembly line. In order to balance workstations, craftsmen must familiarize themselves with each operation and measure work time in the field and adjust the assembly process at any time.