CN111489866A - Production process of special wire harness for new energy automobile - Google Patents
Production process of special wire harness for new energy automobile Download PDFInfo
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- CN111489866A CN111489866A CN202010341208.5A CN202010341208A CN111489866A CN 111489866 A CN111489866 A CN 111489866A CN 202010341208 A CN202010341208 A CN 202010341208A CN 111489866 A CN111489866 A CN 111489866A
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 49
- 239000004020 conductor Substances 0.000 claims abstract description 74
- 238000002788 crimping Methods 0.000 claims abstract description 61
- 238000005520 cutting process Methods 0.000 claims abstract description 25
- 238000012360 testing method Methods 0.000 claims abstract description 19
- 238000007789 sealing Methods 0.000 claims abstract description 17
- 239000003292 glue Substances 0.000 claims abstract description 13
- 230000000149 penetrating effect Effects 0.000 claims abstract description 12
- 238000003466 welding Methods 0.000 claims abstract description 9
- 238000004804 winding Methods 0.000 claims abstract description 9
- 239000000463 material Substances 0.000 claims abstract description 6
- 238000010438 heat treatment Methods 0.000 claims abstract description 4
- 238000004806 packaging method and process Methods 0.000 claims abstract description 4
- 238000000034 method Methods 0.000 claims description 16
- 238000009966 trimming Methods 0.000 claims description 15
- 238000013461 design Methods 0.000 claims description 13
- 238000003825 pressing Methods 0.000 claims description 13
- 206010040844 Skin exfoliation Diseases 0.000 claims description 6
- 239000002390 adhesive tape Substances 0.000 claims description 6
- 238000007689 inspection Methods 0.000 claims description 6
- 239000000853 adhesive Substances 0.000 claims description 4
- 230000001070 adhesive effect Effects 0.000 claims description 4
- 238000005452 bending Methods 0.000 claims description 3
- 238000009960 carding Methods 0.000 claims description 3
- 230000007547 defect Effects 0.000 claims description 3
- 238000001035 drying Methods 0.000 claims description 3
- 239000004744 fabric Substances 0.000 claims description 3
- 238000009434 installation Methods 0.000 claims description 3
- 239000012212 insulator Substances 0.000 claims description 3
- 238000012805 post-processing Methods 0.000 claims description 3
- 238000002360 preparation method Methods 0.000 claims description 3
- 238000003892 spreading Methods 0.000 claims description 3
- 230000008901 benefit Effects 0.000 abstract description 3
- 238000012797 qualification Methods 0.000 abstract description 3
- 238000005516 engineering process Methods 0.000 description 5
- 238000011161 development Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000000446 fuel Substances 0.000 description 2
- 230000002411 adverse Effects 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
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- 238000005336 cracking Methods 0.000 description 1
- 238000004134 energy conservation Methods 0.000 description 1
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/012—Apparatus or processes specially adapted for manufacturing conductors or cables for manufacturing wire harnesses
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/012—Apparatus or processes specially adapted for manufacturing conductors or cables for manufacturing wire harnesses
- H01B13/01263—Tying, wrapping, binding, lacing, strapping or sheathing harnesses
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Abstract
The invention discloses a production process of a new energy automobile special wire harness, which comprises the following steps: s1, preparing materials; s2, cutting; s3, pre-penetrating main conductors into holes of a sheath sealing rear cover, installing sealing plugs, dividing each main conductor into an A end and a B end, wherein one end close to the sealing plugs is the main conductor A end, the other end is the main conductor B end, performing shielding ring crimping treatment on the A ends of the two main conductors, assembling a high-voltage sheath, performing shielding ring crimping treatment on the B ends of the two main conductors, fixing the two single auxiliary conductors and the two main conductors, stranding, pre-installing a black double-wall heat-shrinkable tube, performing ultrasonic welding, and heating the black double-wall heat-shrinkable tube; s4, winding glue for assembly; and S5, performing drawing test, conduction test, size test, appearance test and finished product packaging, and warehousing qualified finished products to finish the production process of the new energy automobile special wire harness. The production process provided by the invention has the advantages of high qualification rate, excellent performance of the produced wire harness and long service life.
Description
Technical Field
The invention relates to the technical field of wire harness production processes, in particular to a production process of a wire harness special for a new energy automobile.
Background
The new energy automobile is an automobile which adopts unconventional automobile fuel as a power source, integrates advanced technologies in the aspects of vehicle power control and driving, and is advanced in technical principle, new in technology and new in structure. The new energy automobile has the advantages of fuel energy conservation, less exhaust emission, environmental friendliness, high efficiency and the like, so that the usage amount of the new energy automobile is increased year by year in recent years, and the new energy automobile also becomes the development trend of the automobile in the future. And the wiring harness is a carrier for the circuit of the new energy automobile and plays a crucial role in the whole operation process of the new energy automobile. In the running process of a new energy automobile, particularly an electric automobile, power is from a battery system, and a wire harness is a carrier for direct current transmission, so that the linear speed used by the new energy automobile is required to have new energy such as high voltage, large current, high temperature resistance and the like. Because new energy vehicles are developed in recent years, the supply capacity of auxiliary materials of the new energy vehicles is still insufficient, for example, the conventional wiring harness production process cannot meet the high requirements of wiring harnesses for the new energy vehicles, and the existing wiring harness production enterprises for the new energy vehicles are few, the technology is not mature enough, the qualified rate of finished wiring harness products obtained by production is low, the service life of the wiring harnesses is short, and the like. Therefore, a simple and efficient wire harness production process for the new energy automobile is sought, and the excellent product performance is a problem to be solved urgently by wire harness production enterprises.
Disclosure of Invention
The invention aims to solve the problems that the production technology of the wire harness is immature, the production yield is low and the service life of the produced wire harness is short in the prior art, and provides a production process of the wire harness special for a new energy automobile.
A production process of a new energy automobile special wire harness comprises the following steps:
s1, preparation: preparing materials required by the production of the wire harness;
s2, tangent line: whether inspection leading wire size accords with the design requirement, if accord with the requirement and fix a position the leading wire of waiting to cut according to the design requirement, tangent line position insulating skin is peeled off length and the required ratio of peeling off length of design and is 2 ~ 2.5: 3, cutting a line perpendicular to the axial direction of the main conductor, and performing appearance inspection, wherein the qualified standards are the defects of no core wire breakage, uneven core wires, damaged core wires, core wire bending, wire skin residue and no rubber skin stripping;
s3, pre-assembling, crimping, stranding and ultrasonic welding: pre-penetrating two main conductors cut in the step S2 into different holes of a sealed rear cover of the same sheath, respectively installing the main conductors into sealing plugs, dividing each main conductor into an A end and a B end, taking one end close to the sealing plug as a main conductor A end, taking one end close to the sealed rear cover of the sheath as a main conductor B end, carrying out shielding ring crimping treatment on the A ends of the two main conductors, assembling a high-pressure sheath, carrying out shielding ring crimping treatment on the B ends of the two main conductors, stripping the two single auxiliary conductors, respectively fixing the two single auxiliary conductors with the two main conductors, then pre-installing a black double-wall heat-shrinkable tube on the two single auxiliary conductors, carrying out ultrasonic welding and heating the black double-wall heat-shrinkable tube;
s4, winding glue and assembling: winding 1-2 circles of PVC adhesive tape on the main guide wire, winding 30-50 mm of orange cloth-based adhesive tape on the corrugated pipe, wherein the distance between the corrugated pipe and the root of the sheath is 20 mm;
s5, post-processing: and carrying out drawing test, conduction test, size test, appearance test and finished product packaging, and warehousing qualified finished products to finish the production process of the new energy automobile special wire harness.
Preferably, in step S3, the pressure welding process of the shield ring at the end a of the main conductor includes the following steps:
A. carding the shielding layer: integrally flanging the shielding layer at the end A of the main guide line, wherein no residual flying wire is left in the flanging;
B. cutting: carrying out the thread cutting operation of the step S2 on the inner core at the end A of the main guide thread;
C. sleeving a shielding ring: installing a sheath shielding inner ring, ensuring that the sheath shielding inner ring is flush with an outer skin peeling port, installing a sheath shielding outer ring matched with the sheath shielding inner ring outside the shielding layer, uniformly spreading the shielding layer on the sheath shielding inner ring, enabling the middle position of the sheath shielding outer ring to abut against a notch, trimming the shielding layer, wherein the wire skin cannot be scratched, the shielding layer does not have residual flying wires, and the thickness of the shielding layer after trimming cannot exceed 1 mm;
D. crimping a terminal: c, placing the terminal under a pressing sheet in a mold, ensuring that two sides of a terminal grabbing part are equal, and placing the end A of the main conducting wire processed in the step C in the terminal for pressing;
E. crimping the shielding ring: the shielding ring rear ring is crimped by using a hexagonal crimping machine, the shielding inner ring and the shielding outer ring are parallel and level during crimping, the crimping is firm and reliable, a shielding layer cannot be exposed, an insulating skin and a wire core cannot be damaged, and the crimping treatment of the shielding ring at the end A of the main conductor is finished.
Preferably, in step D, when the main conductor a is placed in the terminal, the main conductor core wires exposed at both sides of the conductor grasping portion of the terminal are within the terminal installation specification range, and the ratio of the length of the main conductor core wire exposed between the conductor grasping portion and the insulator grasping portion to the length of the skin of the exposed main conductor is 1: 1.
preferably, in step E, the outer shielding ring is 18.1mm to 20.1mm away from the front root of the terminal after the shielding ring is crimped.
Preferably, in step S3, the assembling the high voltage sheath includes the following steps:
a. subpackaging: the crimping areas of the A-end terminals of the two main guide wires are upward, the A-end terminals are inserted into the high-pressure sheath in the same direction, the sealing plug is pushed tightly, and the positioning clamp is installed;
b. cutting, installing a corrugated pipe and installing a wire frame component: cutting the corrugated pipe according to design requirements, penetrating the corrugated pipe from the end B of the main guide wire, respectively installing the main guide wire fixing terminals from the end B of the two main guide wires, clamping by using a tool clamp, then installing the two main guide wires in two hole sealing plugs in the same wire passing frame, and then installing the wire passing frame;
c. fixing the corrugated pipe and the wire passing frame component: the wire passing frame moves towards the main wire guide fixing terminal to move, the main wire guide and the corrugated pipe are bent to the end, close to the main wire guide fixing terminal, of the corrugated pipe and clamped on the clamping groove of the wire passing frame, then the wire passing frame cover is installed, and the locking point of the wire passing frame cover is locked, so that the high-voltage sheath is assembled.
Preferably, in the step c, when the main guide wire and the corrugated pipe are bent, the wing end of the wire passing frame faces upwards and is bent until the corrugated pipe is close to the fixed terminal end of the main guide wire and the 3-4-tooth corrugated pipe is tightly clamped on the clamping groove of the wire passing frame.
Preferably, in step S3, the main conductor B-end shield ring crimping process includes the following steps:
i, trimming a shielding layer: stripping off the outer skin of the main guide wire, and trimming the shielding layer until the length of the shielding layer is 5-6 mm;
II, mounting a shielding ring: firstly, pre-penetrating a shielding outer ring to the outside of a main lead, installing a shielding inner ring on a shielding layer, and integrally flanging the shielding layer to wrap the shielding inner ring;
III, crimping the shielding ring: crimping the shielding outer ring, penetrating a tape adhesive heat-shrinkable tube at the clamping position, trimming the redundant shielding layer after crimping is finished, and thermally drying the tape adhesive heat-shrinkable tube in the middle;
IV, cutting and crimping terminal: and (5) cutting the end B of the main conductor according to the operation step of the step S2, pre-installing the black heat-shrinkable tube without glue, then pressing and connecting the terminal, and baking the black heat-shrinkable tube without glue to finish the pressing and connecting treatment of the shielding ring at the end B of the main conductor.
Preferably, in step S3, the method for fixing the single auxiliary conductor to the main conductor is to peel off the end of the single auxiliary conductor, attach the single auxiliary conductor to the shielding layer before crimping the shielding outer ring in step iii, and then fix the single auxiliary conductor to the main conductor along with the operation of crimping the shielding outer ring.
The production process provided by the invention has complete flow and detailed content, forms a complete production flow of the wire harness for the new energy automobile by preparing materials, cutting, pre-assembling, crimping, stranding, ultrasonic welding, glue winding and assembling, and aims at the problems in the prior art, reduces the problems encountered in the traditional production by strictly controlling special production parameters in the production process, further improves the product qualification rate, reduces the output of unqualified products, improves the utilization rate of raw materials, ensures the production efficiency, particularly controls the ratio of the stripping length of the insulating skin at the cutting line position to the stripping length required by design in the cutting line process, ensures the electrifying characteristic of a lead, controls the position relation between a main lead A and a terminal conductor clamping part and an insulating body clamping part in the crimping operation, ensures the accuracy of crimping, and avoids the adverse effects of poor crimping on the product performance such as resistance rise, The tensile strength is weakened, and the negative effects on subsequent production, product percent of pass, product performance, production efficiency and production cost caused by the problems of terminal deformation and cracking, broken line at the edge of the conductor grabbing part, poor or damaged embedding part, poor pressing and the like are avoided; in addition, in the crimping process, the three processes are strictly controlled in a mode of combining the crimping treatment of the shielding ring at the end A of the main conductor, the assembling of the high-voltage sheath and the crimping treatment of the shielding ring at the end B of the main conductor, so that the product percent of pass is obviously improved, the excellent characteristics of the produced wire harness are ensured, the problems of immature production technology, low production percent of pass and short service life of the produced wire harness of the existing wire harness are effectively avoided, and the wire harness crimping method has considerable development prospect and good social benefit.
Drawings
FIG. 1 is a production process flow chart of a new energy automobile special wire harness provided by the invention;
FIG. 2 is a diagram of a BK5.5-5 terminal analytical measurement system in an embodiment of the present invention;
FIG. 3 is a diagram of a product according to an embodiment of the invention.
Detailed Description
The present invention will be further illustrated with reference to the following specific examples.
Examples
The invention provides a production process of a new energy automobile special wire harness, which comprises the following steps:
s1, preparation: preparing materials required by the production of the wire harness;
s2, tangent line: whether inspection leading wire size accords with the design requirement, if accord with the requirement and fix a position the leading wire of waiting to cut according to the design requirement, tangent line position insulating skin is peeled off length and the required ratio of peeling off length of design and is 2: 3, cutting a line perpendicular to the axial direction of the main conductor, and performing appearance inspection, wherein the qualified standards are the defects of no core wire breakage, uneven core wires, damaged core wires, core wire bending, wire skin residue and no rubber skin stripping;
s3, pre-assembling, crimping, stranding and ultrasonic welding: pre-threading two main guide lines tangent in the step S2 into different holes of the same sheath sealing rear cover, then respectively installing the main guide lines into sealing plugs, dividing each main guide line into two ends A and B, wherein one end close to the sealing plugs is a main guide line A end, and one end close to the sheath sealing rear cover is a main guide line B end;
the method for carrying out the crimping treatment on the shielding rings at the A ends of the two main conducting wires comprises the following steps:
A. carding the shielding layer: integrally flanging the shielding layer at the end A of the main guide line, wherein no residual flying wire is left in the flanging;
B. cutting: carrying out the thread cutting operation of the step S2 on the inner core at the end A of the main guide thread;
C. sleeving a shielding ring: installing a sheath shielding inner ring, ensuring that the sheath shielding inner ring is flush with an outer skin peeling port, installing a sheath shielding outer ring matched with the sheath shielding inner ring outside the shielding layer, uniformly spreading the shielding layer on the sheath shielding inner ring, enabling the middle position of the sheath shielding outer ring to abut against a notch, trimming the shielding layer, wherein the wire skin cannot be scratched, the shielding layer does not have residual flying wires, and the thickness of the shielding layer after trimming cannot exceed 1 mm;
D. crimping a terminal: arrange the terminal in the mould under the preforming, guarantee that the terminal grabs to close a both sides impartially, place the leading wire A end after step C handles in the terminal, the conductor of terminal grabs to close the exposed leading wire heart yearn in terminal installation specification within range in a both sides, and the conductor grabs to close and the insulator grabs to close and to close between the portion exposed leading wire heart yearn length and the ratio of exposed leading wire skin length is 1: 1, pressing;
E. crimping the shielding ring: the rear ring of the shielding ring is crimped by using a hexagonal crimping machine, the shielding inner ring and the shielding outer ring are parallel and level during crimping, the crimping is firm and reliable, a shielding layer cannot be exposed, an insulating skin and a wire core cannot be damaged, the distance between the shielding outer ring and the front root of the terminal is 19.1mm, and then the crimping treatment of the shielding ring at the A end of the main conductor is completed.
Assembling a high-pressure sheath, comprising the steps of:
a. subpackaging: the crimping areas of the A-end terminals of the two main guide wires are upward, the A-end terminals are inserted into the high-pressure sheath in the same direction, the sealing plug is pushed tightly, and the positioning clamp is installed;
b. cutting, installing a corrugated pipe and installing a wire frame component: cutting the corrugated pipe according to design requirements, penetrating the corrugated pipe from the end B of the main guide wire, respectively installing the main guide wire fixing terminals from the end B of the two main guide wires, clamping by using a tool clamp, then installing the two main guide wires in two hole sealing plugs in the same wire passing frame, and then installing the wire passing frame;
c. fixing the corrugated pipe and the wire passing frame component: the wire passing frame moves towards the main wire guide fixing terminal and moves, the wing end of the wire passing frame faces upwards, the main wire guide and the corrugated pipe are bent until the corrugated pipe is close to the main wire guide fixing terminal end and the 3-4-tooth corrugated pipe is clamped on the clamping groove of the wire passing frame, the wire passing frame cover is installed, the locking point of the wire passing frame cover is locked, and then the high-voltage sheath is assembled.
The method for carrying out the crimping treatment on the shielding rings at the B ends of the two main conducting wires comprises the following steps:
i, trimming a shielding layer: stripping off the outer skin of the main guide wire, and trimming the shielding layer until the length of the shielding layer is 5-6 mm;
II, mounting a shielding ring: firstly, pre-penetrating a shielding outer ring to the outside of a main lead, installing a shielding inner ring on a shielding layer, and integrally flanging the shielding layer to wrap the shielding inner ring;
III, crimping the shielding ring: crimping the shielding outer ring, penetrating a phi 6.4 x 35 heat-shrinkable tube with glue at the clamping position, trimming the redundant shielding layer after crimping is finished, and performing thermal drying on the phi 6.4 x 35 heat-shrinkable tube with glue in the middle;
IV, cutting and crimping terminal: and (4) cutting the end B of the main conducting wire according to the operation step of the step S2, pre-installing the phi 5 x 35 black heat-shrinkable tube without glue, then pressing and connecting the terminal BK5.5-5, and thermally baking the phi 5 x 35 black heat-shrinkable tube without glue, thereby completing the pressing and connecting treatment of the shielding ring at the end B of the main conducting wire.
Stripping a single auxiliary lead, attaching the single auxiliary lead to the shielding layer before crimping the shielding outer ring in the step III, fixing the single auxiliary lead to the main lead along with the operation of crimping the shielding outer ring, twisting two single auxiliary leads, pre-installing the phi 3.2 x 35 black double-wall heat-shrinkable tube, performing ultrasonic welding, and heating the phi 3.2 x 35 black double-wall heat-shrinkable tube;
s4, winding glue and assembling: 2 circles of PVC adhesive tapes are wound on the main guide wire, the distance between the corrugated pipe and the root of the sheath is 20mm, and 40mm of orange cloth-based adhesive tape is wound on the corrugated pipe;
s5, post-processing: and carrying out drawing test, conduction test, size test, appearance test and finished product packaging, and warehousing qualified finished products to finish the production process of the new energy automobile special wire harness.
The same part used for the same new energy automobile is produced by the processes of the embodiment and the existing wiring harness production respectively, the qualification rate and the product performance of the two production processes are evaluated respectively, the produced wiring harness is subjected to service life, high pressure resistance and high temperature resistance tests, the process result of the existing wiring harness production is taken as a standard, the embodiment is judged, and the result is as follows:
| examples | Existing production process | |
| Percent of pass | +18.8％ | —— |
| Service life | +8.3％ | —— |
| Withstand voltage test | +3.2％ | —— |
| High temperature resistance test | +5.9％ | —— |
In the table, "+" indicates that the examples are improved compared to the corresponding items of the existing production process.
The experimental result shows that compared with the existing production process, the yield, the service life of the product, the pressure resistance and the high-temperature resistance of the product are obviously improved.
The above description is only for the preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art should be considered to be within the technical scope of the present invention, and the technical solutions and the inventive concepts thereof according to the present invention should be equivalent or changed within the scope of the present invention.
Claims (8)
1. A production process of a special wire harness for a new energy automobile is characterized by comprising the following steps:
s1, preparation: preparing materials required by the production of the wire harness;
s2, tangent line: whether inspection leading wire size accords with the design requirement, if accord with the requirement and fix a position the leading wire of waiting to cut according to the design requirement, tangent line position insulating skin is peeled off length and the required ratio of peeling off length of design and is 2 ~ 2.5: 3, cutting a line perpendicular to the axial direction of the main conductor, and performing appearance inspection, wherein the qualified standards are the defects of no core wire breakage, uneven core wires, damaged core wires, core wire bending, wire skin residue and no rubber skin stripping;
s3, pre-assembling, crimping, stranding and ultrasonic welding: pre-penetrating two main conductors cut in the step S2 into different holes of a sealed rear cover of the same sheath, respectively installing the main conductors into sealing plugs, dividing each main conductor into an A end and a B end, taking one end close to the sealing plug as a main conductor A end, taking one end close to the sealed rear cover of the sheath as a main conductor B end, carrying out shielding ring crimping treatment on the A ends of the two main conductors, assembling a high-pressure sheath, carrying out shielding ring crimping treatment on the B ends of the two main conductors, stripping the two single auxiliary conductors, respectively fixing the two single auxiliary conductors with the two main conductors, then pre-installing a black double-wall heat-shrinkable tube on the two single auxiliary conductors, carrying out ultrasonic welding and heating the black double-wall heat-shrinkable tube;
s4, winding glue and assembling: winding 1-2 circles of PVC adhesive tape on the main guide wire, winding 30-50 mm of orange cloth-based adhesive tape on the corrugated pipe, wherein the distance between the corrugated pipe and the root of the sheath is 20 mm;
s5, post-processing: and carrying out drawing test, conduction test, size test, appearance test and finished product packaging, and warehousing qualified finished products to finish the production process of the new energy automobile special wire harness.
2. The production process of the wire harness special for the new energy automobile as claimed in claim 1, wherein in step S3, the main conductor a-end shield ring crimping process includes the steps of:
A. carding the shielding layer: integrally flanging the shielding layer at the end A of the main guide line, wherein no residual flying wire is left in the flanging;
B. cutting: carrying out the thread cutting operation of the step S2 on the inner core at the end A of the main guide thread;
C. sleeving a shielding ring: installing a sheath shielding inner ring, ensuring that the sheath shielding inner ring is flush with an outer skin peeling port, installing a sheath shielding outer ring matched with the sheath shielding inner ring outside the shielding layer, uniformly spreading the shielding layer on the sheath shielding inner ring, enabling the middle position of the sheath shielding outer ring to abut against a notch, trimming the shielding layer, wherein the wire skin cannot be scratched, the shielding layer does not have residual flying wires, and the thickness of the shielding layer after trimming cannot exceed 1 mm;
D. crimping a terminal: c, placing the terminal under a pressing sheet in a mold, ensuring that two sides of a terminal grabbing part are equal, and placing the end A of the main conducting wire processed in the step C in the terminal for pressing;
E. crimping the shielding ring: the shielding ring rear ring is crimped by using a hexagonal crimping machine, the shielding inner ring and the shielding outer ring are parallel and level during crimping, the crimping is firm and reliable, a shielding layer cannot be exposed, an insulating skin and a wire core cannot be damaged, and the crimping treatment of the shielding ring at the end A of the main conductor is finished.
3. The production process of the wire harness special for the new energy automobile according to claim 2, wherein in the step D, when the main conductor A is placed in the terminal, the main conductor core wires exposed at two sides of the conductor catching part of the terminal are in the terminal installation specification range, and the ratio of the length of the main conductor core wire exposed between the conductor catching part and the insulator catching part to the length of the main conductor skin exposed is 1: 1.
4. the production process of the special wire harness for the new energy automobile according to claim 2, wherein in the step E, the distance between the shielding outer ring and the front root of the terminal is 18.1 mm-20.1 mm after the shielding ring is connected in a pressing mode.
5. The production process of the new energy automobile dedicated wire harness according to claim 1, wherein in the step S3, the assembling of the high voltage sheath comprises the following steps:
a. subpackaging: the crimping areas of the A-end terminals of the two main guide wires are upward, the A-end terminals are inserted into the high-pressure sheath in the same direction, the sealing plug is pushed tightly, and the positioning clamp is installed;
b. cutting, installing a corrugated pipe and installing a wire frame component: cutting the corrugated pipe according to design requirements, penetrating the corrugated pipe from the end B of the main guide wire, respectively installing the main guide wire fixing terminals from the end B of the two main guide wires, clamping by using a tool clamp, then installing the two main guide wires in two hole sealing plugs in the same wire passing frame, and then installing the wire passing frame;
c. fixing the corrugated pipe and the wire passing frame component: the wire passing frame moves towards the main wire guide fixing terminal to move, the main wire guide and the corrugated pipe are bent to the end, close to the main wire guide fixing terminal, of the corrugated pipe and clamped on the clamping groove of the wire passing frame, then the wire passing frame cover is installed, and the locking point of the wire passing frame cover is locked, so that the high-voltage sheath is assembled.
6. The production process of the wire harness special for the new energy automobile as claimed in claim 5, wherein in the step c, when the main lead and the corrugated pipe are bent, the wing end of the wire passing frame faces upwards and is bent until the corrugated pipe is clamped on the clamping groove of the wire passing frame by 3-4 teeth of the corrugated pipe close to the fixed terminal end of the main lead.
7. The production process of the wire harness special for the new energy automobile as claimed in claim 1, wherein in step S3, the main conductor B-end shield ring crimping process includes the steps of:
i, trimming a shielding layer: stripping off the outer skin of the main guide wire, and trimming the shielding layer until the length of the shielding layer is 5-6 mm;
II, mounting a shielding ring: firstly, pre-penetrating a shielding outer ring to the outside of a main lead, installing a shielding inner ring on a shielding layer, and integrally flanging the shielding layer to wrap the shielding inner ring;
III, crimping the shielding ring: crimping the shielding outer ring, penetrating a tape adhesive heat-shrinkable tube at the clamping position, trimming the redundant shielding layer after crimping is finished, and thermally drying the tape adhesive heat-shrinkable tube in the middle;
IV, cutting and crimping terminal: and (5) cutting the end B of the main conductor according to the operation step of the step S2, pre-installing the black heat-shrinkable tube without glue, then pressing and connecting the terminal, and baking the black heat-shrinkable tube without glue to finish the pressing and connecting treatment of the shielding ring at the end B of the main conductor.
8. The production process of the wire harness special for the new energy automobile as claimed in claim 7, wherein in step S3, the method for fixing the single auxiliary conductor to the main conductor is to peel off the end of the single auxiliary conductor, attach the single auxiliary conductor to the shielding layer before crimping the shielding outer ring in step iii, and then fix the single auxiliary conductor to the main conductor along with the operation of crimping the shielding outer ring.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202010341208.5A CN111489866A (en) | 2020-04-27 | 2020-04-27 | Production process of special wire harness for new energy automobile |
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| Application Number | Priority Date | Filing Date | Title |
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| CN202010341208.5A CN111489866A (en) | 2020-04-27 | 2020-04-27 | Production process of special wire harness for new energy automobile |
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Cited By (11)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN112259297A (en) * | 2020-09-15 | 2021-01-22 | 上海万卡信实业有限公司 | Manufacturing method of fusion-spliced integrated wire harness with multiple wire harness loops communicated |
| CN113131306A (en) * | 2021-05-25 | 2021-07-16 | 扬州市龙川龙车用电器有限公司 | Method for manufacturing corrosion-resistant oxidation-resistant automobile wire harness |
| CN113809612A (en) * | 2021-07-31 | 2021-12-17 | 重庆长安汽车股份有限公司 | Design method of HSD automobile wire harness |
| CN113851280A (en) * | 2021-09-09 | 2021-12-28 | 广州市力可欣电子有限公司 | Production process and equipment for automobile wire harness |
| CN113922187A (en) * | 2021-10-22 | 2022-01-11 | 江苏博之旺自动化设备有限公司 | FAKRA cable processing equipment and method |
| CN113937590A (en) * | 2021-09-06 | 2022-01-14 | 汇铂斯电子技术(苏州)有限公司 | New energy automobile battery wire harness production process |
| CN114172001A (en) * | 2021-12-02 | 2022-03-11 | 芜湖鑫联机电有限公司 | High-performance wire harness production process |
| CN114414195A (en) * | 2021-12-31 | 2022-04-29 | 常熟市虞华真空设备科技有限公司 | Vacuum experimental device and system for planetary atmospheric sound detection research |
| CN114784590A (en) * | 2022-04-06 | 2022-07-22 | 江苏威晟轨道交通科技有限公司 | Crimping process for wire harness production |
| CN115189282A (en) * | 2022-07-15 | 2022-10-14 | 临海市四通制管有限公司 | Production process and production device for wiring harness assembly of automobile front cabin |
| CN115497767A (en) * | 2022-10-25 | 2022-12-20 | 宁波奥博汽车电器有限公司 | Processing technology and equipment for electromagnetic switch of automobile starter |
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Cited By (14)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN112259297A (en) * | 2020-09-15 | 2021-01-22 | 上海万卡信实业有限公司 | Manufacturing method of fusion-spliced integrated wire harness with multiple wire harness loops communicated |
| CN113131306A (en) * | 2021-05-25 | 2021-07-16 | 扬州市龙川龙车用电器有限公司 | Method for manufacturing corrosion-resistant oxidation-resistant automobile wire harness |
| CN113809612A (en) * | 2021-07-31 | 2021-12-17 | 重庆长安汽车股份有限公司 | Design method of HSD automobile wire harness |
| CN113937590A (en) * | 2021-09-06 | 2022-01-14 | 汇铂斯电子技术(苏州)有限公司 | New energy automobile battery wire harness production process |
| CN113851280A (en) * | 2021-09-09 | 2021-12-28 | 广州市力可欣电子有限公司 | Production process and equipment for automobile wire harness |
| CN113922187B (en) * | 2021-10-22 | 2024-05-10 | 江苏博之旺自动化设备有限公司 | FAKRA cable processing equipment and method |
| CN113922187A (en) * | 2021-10-22 | 2022-01-11 | 江苏博之旺自动化设备有限公司 | FAKRA cable processing equipment and method |
| CN114172001A (en) * | 2021-12-02 | 2022-03-11 | 芜湖鑫联机电有限公司 | High-performance wire harness production process |
| CN114172001B (en) * | 2021-12-02 | 2024-04-19 | 芜湖鑫联机电股份有限公司 | High-performance wire harness production process |
| CN114414195A (en) * | 2021-12-31 | 2022-04-29 | 常熟市虞华真空设备科技有限公司 | Vacuum experimental device and system for planetary atmospheric sound detection research |
| CN114784590A (en) * | 2022-04-06 | 2022-07-22 | 江苏威晟轨道交通科技有限公司 | Crimping process for wire harness production |
| CN115189282A (en) * | 2022-07-15 | 2022-10-14 | 临海市四通制管有限公司 | Production process and production device for wiring harness assembly of automobile front cabin |
| CN115497767A (en) * | 2022-10-25 | 2022-12-20 | 宁波奥博汽车电器有限公司 | Processing technology and equipment for electromagnetic switch of automobile starter |
| CN115497767B (en) * | 2022-10-25 | 2023-09-01 | 宁波奥博汽车电器有限公司 | Processing technology and equipment for electromagnetic switch of automobile starter |
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