On the main points of the wiring harness process layout in the vehicle assembly process

1, Introduction
Wiring harness as a necessary part of the vehicle, in the process of vehicle use plays an important role once the wiring harness assembly is not appropriate, the light will appear such as plug connector damage, lights do not light and other impact on the function of electrical appliances; heavy lead to vehicle fire and other accidents. Therefore, the rational assembly of the wiring harness is an important part of the vehicle production process.
Generally speaking, the vehicle needs to be assembled more than a dozen wiring harnesses: engine wiring harness, power harness, fuel injector harness, left and right door harnesses, the body of the main wiring harness, chassis wiring harness, roof harness, back door transition harness, back door harness, side sliding door harness, speaker harnesses and so on.
In most cases, the wiring harness is not in a position by an employee can be arranged to complete, for the length of the long, branching, plug joints more wiring harness, the wiring harness process layout is a need for multi-position, multi-employee cooperation process, in order to make the wiring harness layout is reasonable, does not affect the quality of the assembly of the wiring harness and the operation of the after-processes, need to be standardized for the wiring harness process layout.
2、Wire harness take
The wiring harness can not be taken in the process of pulling the wiring harness branch line, but should grasp the trunk of the wiring harness, the wiring harness straightened out.
3, the direction of the wiring harness branch line for example
Engine wiring harness assembly part of the branch line out of the way: engine wiring harness assembly (shown in Figure 2) has 41 plug connector, 6 iron point, involving ten children and the layout of the post, including with the power harness, engine E-CU, fuel injector harness, water injector motor, wiper motor, left and right wheel speed sensor, left and right headlights, air-conditioning compressor, horn and other parts of the assembly, the assembly process is more complex. The assembly process is relatively complicated. The assembly of this part involves wiring harnesses from the interior wires to the chassis wires and then to the entire vehicle wires.
(1) Problem, the shortness of the wiring harness branch hitch wire during assembly makes it impossible to connect with the corresponding plug connector of other parts.
(2) Analysis, the hitch wire next to the 3 former L sequence has been assembled plug connector, one of the connector a connected to the drying bottle, connector b, c connected to the left headlight. The branch line where these 3 plug connectors are located got entangled with the air conditioning pipe, resulting in the hitch line not being able to be fastened at the fixed point to be assembled (as shown in Fig. 3).
Upon verification of the previous process, the assembly sequence of the parts involved in this area is as follows. Step:A employee will connect the connector a to the drying bottle; Step 2:B employee r= to the air conditioning tube connected to the drying bottle, this step should pay attention to the positional relationship with the branch line where the connector a is located; Step 3:C employee will be connected to the connector h,. connected to the front combination lamp, this step should pay attention to connector B, c where the branch line can not be wrapped around the air conditioning tube; Step 4: Employee D will be the hitch wire fixed to the hitch wire fixing point.
Because employee B in the second step did not pay attention to the positional relationship with the wire harness when assembling the air conditioning tube, and placed the air conditioning tube on top of the wire harness connecting the thousand dry bottles, it caused employee c in the third step to wrap the wire harness around the air conditioning tube when connecting the 2 plug connectors of the left headlight, which led to the discovery of insufficient length of the wire harness by employee D when tightening the hitch wire.
(3) Solution. Improve the arrangement of this section in the process as follows (as shown in Fig. 4): ① Employee B, when assembling the air conditioning pipe, passes the air conditioning pipe from under the branch line that connects to the drying bottle; ② Employee C, when connecting the left headlamp, passes the wiring harness from the outside of the air conditioning pipe and does not entangle it with the air conditioning pipe. By standardizing the above _L art route, the wiring harness and air conditioning tube separate, so that the wiring harness segments are arranged smoothly, and the assembly of the hitch line did not appear again the phenomenon of insufficient length.
4、Wire harness placement position
Because the harness involves assembly of many positions, the process is long, so in the harness is not fixed before, need to be unfixed harness placed in the location of the point to standardize, can not appear in the harness is squeezed, stepped on or by other parts stuck, pinched, scratched, scratched and other phenomena.
Example: Placement point specification of the speaker harness of the side enclosure
(1) Problem, employees feedback in the assembly of the rear side enclosure speakers, the speaker harness to be docked by the first few sequences of assembly of the carpet is pressed underneath, need to take the harness out from under the carpet.
(2) Analyze. The operating time for this step is non-value-added time and does not fit the concept of target time reduction. Moreover, since the wire harness is pressed under the carpet, the officer r. who assembles other parts on the carpet does not notice this wire harness, so there is stepping on the wire harness, which can easily cause the wire harness connector to be stepped on.
(3) The solution requires that the wiring harness be placed between the body side enclosure rice gold, can not be placed on the floor, can not cover, step on the wiring harness (as shown in Figure 5).
5, fixed harness accessories
Should be through a variety of ways to reliably fix the harness in the body or other parts, there shall be no wiring harness randomly shaking the situation.
(1) buckle, buckle is generally accompanied by wire Cambodia with, in the assembly of the buckle directly on the corresponding holes. Harness on the snap positioning is very important, try to snap the position and need to be fixed parts of the hole. If it is a snap that can be slid at will, then the employee still needs to move the snap to the assembly point during assembly, resulting in a waste of time.
(2) wire clips, most of the wire clips are welded from the body of the body with the body with the correct assembly method of wire clips should be from two directions to the harness clamping, and one of the clamps wrapped around the harness, so that the harness does not appear to be loose, shaking and other phenomena.
(3) tie, tie length has a variety of length, in the assembly of the need to choose the appropriate length of the tie, and in the use of the tie to fix the wiring harness, the tie will be too long part of the cut short, so as not to tie too long to affect the assembly of other parts. This method requires the use of scissors and is not as convenient as snap and wire clips in terms of assembly time. As shown in Figure A use the tie to fix the wire harness.
(4) Adhesive tape adhesive tape with a variety of sizes, you should choose the appropriate size of the adhesive tape. Sticky tape should be pressed when pasting, so that the wither tape paste firmly and reliably; and choose a reasonable location, especially to avoid the assembly holes of other parts.
At present, the use of adhesive tape fixed parts only as a short-term auxiliary way, this method is gradually replaced by other methods. The use of adhesive tape for fixing the shortcomings: one is not beautiful, the second is the existence of security and disaster prevention aspects of the hidden danger, the third is the cost is relatively high.
6, Summary
Wiring harness assembly is a complex and important process, this paper elaborates from the wiring harness process layout, the wiring harness layout of the three key points of the analysis of the wiring harness towards the wire requirements, placement requirements, fixed way to analyze and give examples. Explain that the length of the long, branching, plug joints of the wiring harness arrangement is a need for multi-position, multi-personnel cooperation process, from the entire assembly process to consider many factors, including the location of other parts, the impact on the post-processing, whether there is a repeat of the phenomenon of picking up, stepping on, blocking holes and other phenomena. Therefore, craftsmen can only formulate a suitable route by continuously enriching their knowledge and observing more. In addition, when selecting the fixed parts of the harness, the positioning of the fixed parts, length, size requirements and the tools to be selected for assembly and the time required, etc., as far as possible, the harness will be arranged in a smooth and beautiful.

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