In the production of automotive wiring harnesses, there exists a diverse array of specialized equipment. Based on their application within the manufacturing process, these can be broadly categorized into four types: front-end process equipment, pre-assembly and assembly equipment, testing devices, and environmental testing equipment.
Front-End Process Equipment
The front-end processes encompass wire cutting, stripping, twisting, inserting waterproof plugs, and crimping terminals. This stage is characterized by a high degree of automation in the processing of automotive wiring harnesses. Front-end process equipment can be classified by functionality into single-process devices, computer-controlled cutting and stripping machines, semi-automatic terminal crimping machines, and fully automatic terminal crimping machines. These can seamlessly crimp and assemble harness sheathing, along with automated manufacturing devices like ultrasonic terminal welding machines. Wiring harness manufacturers can allocate automated manufacturing equipment according to the specific technological requirements of their products.
Also known as fully automatic terminal insertion machines, these devices enable comprehensive automation of wire processing, stripping, waterproof plug insertion, terminal crimping, and sheathing assembly. However, the high manufacturing costs of such equipment make them more suitable for projects that involve a narrow range of products and large batch sizes. Terminal crimping dies represent the most widely utilized tooling equipment in the front-end processes. Generally, wiring harness companies possess hundreds of sets of crimping dies of various specifications and models. Although many connector manufacturers sell crimping dies corresponding to their terminal products, due to factors such as compatibility with crimping machines and price considerations, harness manufacturers often opt for customized solutions from specialized equipment vendors.
Pre-Assembly and Assembly Equipment
The pre-assembly and assembly process includes inserting closed-end protective tubes, blind plugs, assembling sheaths, bundling and covering wiring harnesses, and inserting rubber components. The degree of automation in this stage is relatively low, typically performed by operators on assembly lines or workstations with the aid of tools. The process utilizes minimal auxiliary devices and tools, mostly comprising semi-automatic equipment or simple mechanical tools, such as automatic plastic component inserters, automatic blind plug inserters, rubber component reamers, automatic coating machines, heat shrink machines, tie gun tools, and terminal extraction tools. The pre-assembly and assembly phase is currently the most labor-intensive part of automotive wiring harness processing, significantly contributing to the classification of the automotive wiring harness industry as labor-intensive.
Testing Equipment
Similar to testing processes, testing equipment can be divided into semi-finished product testing devices and finished product testing devices.
A. Semi-Finished Product Testing Devices
These include independent quality inspection tools and equipment, as well as monitoring systems integrated into fully automatic devices. Independent quality testing tools encompass crimp pull testers, micrometers, and terminal cross-section inspection stations. The monitoring systems of fully automatic devices consist of pressure monitors, color detection and recognition instruments, and defective product cutoff devices. These tools are primarily employed to assess and monitor the quality of semi-finished products during the front-end processes of automotive wiring harness manufacturing.
B. Finished Product Testing Devices
Testing equipment for finished products mainly refers to continuity testing stations. Given the stringent quality control requirements associated with automotive wiring harness products, continuity testing stations are essential equipment for harness manufacturers. These stations range from simple devices that test electrical continuity to comprehensive systems that utilize infrared and photoelectric methods to thoroughly evaluate the integrity, continuity, airtightness, and accuracy of the harnesses, along with printing test labels.
Environmental Testing Equipment
Environmental testing equipment is utilized to assess the quality stability and aging resistance of wiring harnesses under the complex working conditions of automobiles. This equipment can conduct environmental tests and analyses of automotive wiring harness products according to varying customer requirements. It encompasses various testing protocols, including electrical performance tests, reliability and durability assessments, material and component analysis, size and fit measurement, as well as mechanical performance evaluations. Environmental testing equipment is not exclusively designated for automotive wiring harnesses.
With the above four types of dedicated equipment, automotive wire harness manufacturers can effectively improve production efficiency and ensure product quality to meet the increasingly stringent technical requirements of the automotive industry.