I. Core production process
1. Engineering design stage
3D wire laying: CATIA/Electric Harness Design module simulates the wiring of the whole vehicle.
Lead wire selection: select wire diameter according to current load (0.13mm²~120mm²)
Terminal matching: AMP/TE Connectivity database selection (gold plated/tin plated/silver plated)
Protective design: Bellows (Φ5~Φ80), tape wrapping (PVC/ fabric base / flannelette)
II. Preparation of raw materials
Pre-treatment of wires: stranding of copper wires→extrusion of insulation layer (XLPE/PVC)→laser coding (wire number + batch)
Stamping of terminals: continuous die stamping of 0.5mm copper tape (accuracy ±0.01mm)
Manufacture of injection molded parts: PA66+GF30 material injection connector shell (waterproof grade IP6K9K)
III. Wire harness assembly line
Key process control points:
Crimp height: 0.8±0.03mm (micrometer sampling inspection)
Tensile test: wire and terminal＞80N (ISO 8092 standard)
Conductivity test: 100% full inspection (resistance <10mΩ)
IV. Quality verification system
Electrical test:
Voltage withstand test: AC 1500V/3s (insulation resistance ＞100mΩ)
Instantaneous break detection: microsecond break monitoring in vibration
Environmental test:
Temperature cycling: -40℃↔125℃/1000 times (ISO 16750)
Salt spray test: 96h@5% NaCl solution
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