Requirements Analysis: It begins with a meeting with the customer to understand the specific harness requirements, including length, configuration, materials and connectors.Diagram Making: Engineers create detailed diagrams and design specifications based on project requirements.Materials Selection: In this phase, the most suitable materials are selected for each application, ensuring that they comply with the required safety and durability regulations.
2. Cable Cutting and Preparation
Measuring and Cutting: Cables are cut to specified length, following exact measurements to ensure consistency in each harness.Cable Stripping:Then, the ends of the cables are stripped to expose the conductors. This is done in a precise manner to ensure a correct connection.Identification and Labeling: Wires are labeled to facilitate the assembly process and ensure that each wire is in the correct place within the harness.
3. Crimping and/or Soldering
Crimping Terminals: Terminals are crimped onto the ends of cables to provide a secure and reliable connection. Crimping is performed using specialized tools to ensure a perfect fit.Welding (if necessary): In some cases, soldering is performed to ensure a stronger, more durable electrical connection, especially in high-demand applications.
4. Assembly of Connectors and Components
Connecting Components: Wires and terminals are connected to the corresponding connectors according to the specified layout.Adjustment of Auxiliary Components: Auxiliary components such as protectors, covers or clamps are added to ensure that the harness has a robust and tidy structure.
Cable Management: Cables are grouped and organized for easy management and to reduce the risk of tangles or damage.Banding or taping: Bundled cables are wrapped with tape or insulating material to ensure that the harness is protected and has a compact and uniform structure.
Visual Inspection: A detailed visual inspection is performed to verify that the harness meets specifications and does not have any visible defects.Continuity and Isolation Test: Continuity tests are carried out to ensure that each connection is correctly made and the insulation is checked to avoid possible short circuits.Functional Testing (if applicable): In some cases, additional functional testing is performed to verify harness performance under conditions similar to its final application.
7. Packaging and Delivery
Safe Packaging: Completed harnesses are carefully packed to protect them during shipping.Shipping to Customer: Finally, the harness is sent to the customer along with the necessary documentation, ensuring that it is ready for immediate use.
