A Brief Talk on Wire Harness Processing from Kable-X

1. Incoming materials inspection: conduct environmental protection test by ROHS machine to test whether they are conforming to ROHS standard.

    Device needed: ROHS tester

    Technological requirement: the incoming materials must not include hazardous substance like Pb, Hg, Cd, PBB, PBDE and etc.

2. Wire feeding: feed the wires to be processed onto the transfer wire rack.

    Device needed: wires feeding rack

    Technological requirement: do not abrade the wire surface.

3. Wire cutting: cut the wires to required length with wire cutting machine.

    Device needed: computerized wire cutting machine

     Technological requirement: do not break the wire surface; do not cut off the copper strand; the jacket stripping tolerance must not over ±1mm;

4. Wire stripping: strip the wire jacket to the required length at the connection end according to SOP.

    Device needed: pneumatic jacket stripping machine

    Technological requirement: do not crush the wire surface; the jacket stripping tolerance must not over ±1mm;

5. Wire twisiting: arrange the conductor at the connection end and twist it.

     Device needed: wires twister

    Technological requirement: do not abrade the wire surface; twist the conductor firmly without scattered strand;

6. Terminal crimping: crimp the conductor at the end to the terminal.

     Device needed: crimping machine

     Technological requirement: no terminal deformation; crimp the terminals to the required height and width and the crimped terminals should resist against certain pulling force;

7. Assembly: assemble the connectors and plugs.

   Device needed: electric screw driver

   Technological requirement: the screw must not protrude the connector surface; the wire harness should reach certain twsiting force;

8. Conduction test: do conduction test with tester.

     Device needed: conduction tester

    Technological requirement: no defects like short circuit, open circuit, wires mismatch, poor contact, low insulation and etc.

9. Packaging: pack the wire harness with plastic bag and put into cartons.

    Device needed: sealing machine and packer

     Technological requirement: smooth seal; wrap the carton firmly with tapes;