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Selection of tooling materials for automobile wiring harness

release time:2021-07-08publisher:Howdy

  The tooling of the automobile wiring harness production workshop is generally composed of lean tubes, aluminum profiles, square steel tubes, composite wood panels, plexiglass panels, steel plates, glass, POM modules, etc., which are combined by clamping fixture buckles for clamping connection and welding. In the planning and production of tooling racks, tooling tables, turnover carts, simple storage containers, etc. Next, we will analyze the advantages and disadvantages of using different materials, and provide reference for the planning and production of wiring harness tooling.

  1, lean tube

   Lean tube is a plastic-coated shaped steel tube. The steel tube is round steel tube. The diameter of the standard lean tube is 28mm and the wall thickness of the steel tube is 1.0mm. Lean tubes with inner walls of 0.8mm and 1.2mm are also available on the market. Lean tube assembly is an assembled product composed of tube fittings and tube chain fasteners, which can transform creative planning into practical assembled products, and the production and assembly process is extremely simple and convenient. Because of the low price of lean pipes, modern industries often assemble and manufacture some lean pipe racks, workbenches, lean pipe racks, lean pipe turnover carts, lean pipe assembly lines, etc., and because the lean pipes are easy to disassemble and assemble, they are now It is widely used in diversified production occupations such as the automobile industry, wire harness manufacturing industry, and electronic product manufacturing industry.

   (1) Selection of lean tube in wire harness manufacturing industry

  In the wire harness processing process, you can choose lean tube planning to make sensitive and changeable supporting tooling racks for different wire harness product planning. Now it is mainly used for the pre-assembly process in the wire harness processing process, as shown in Figure 1. This kind of tooling rack can be satisfied with the processing of different wiring harness varieties in the early stage of planning, such as cabin wiring harness, the length of the wire type is different, the square of the wire is different in size, and the messy punching line is not easy to draw. Choose the pre-installed rack of lean tube planning, and choose the layered multi-cylinder method to satisfy the problem of different wire lengths; you can choose different types of standard PVC square cylinders to deal with the problem of large differences in the size of the conductor square; you can choose vertical To deal with the problem that it is not easy to draw the wire in the wiring harness of the engine room, it is not easy to draw the wire.

   Like car body wiring harness, the line type is mainly long, which mainly affects the pre-installation of body wiring harness

In order to satisfy this requirement, we use lean management to plan similar supermarket racks, and layer reinforcements, so that the wires can be looped repeatedly in limited places, so as to reduce the constraints of the car body wiring harness on the place requirements; such as the surface The wiring harness and wires are mainly based on a variety of check-in lines. When the lean tube is selected for pre-installation, the multi-tube and multi-rod support method can be used to satisfy the problem of the problem of too many check-in lines on the surface wiring harness and inconvenient placement; such as engine wiring harness, multiple wires There are crimped waterproof plugs. When planning the engine pre-installation frame, we can choose the PVC square tube with a large opening.

The assembly process of the wiring harness supporting line is shown in Figure 2. At the beginning of the planning, this kind of tooling rack needs to take into account the simplicity of the wiring harness supporting line, the simple data, and the single requirements for the place. When we choose the lean pipe planning supporting line assembly rack, The commonality of this kind of tooling rack can be fully considered, and a single supporting line assembly rack can produce supporting lines that do not require any type of wiring harness. The wiring harness turnover process is shown in Figure 3. In view of the frequent turnover characteristics of the wiring harness processing process, the use of lean tube planning turnover racks can effectively satisfy the different needs of each process of wire harness processing, such as the product line turnover process, the use of lean tube planning, in We are satisfied with the turnover ability to the greatest extent, and can also change and improve the turnover rack according to the change of the packing box standard.

The special process supporting tooling with special characteristics of the wiring harness is shown in Figure 4. Now some wiring harnesses are in the early planning stage, and some wiring harnesses are installed in the car. There are special requirements for the processing procedures of the wiring harness. Use lean pipes to plan the tooling with special characteristics. Frame, can flexibly improve and optimize the processing of different wire harness varieties.

   (2) The selection of lean tube has the following characteristics

  1) Low price. It can directly reduce the cost of tooling in the production process. Because of the diversity of wire harness processing occupations, such as the use of special tooling planning for different wire harnesses, the cost of wire harness processing will be very expensive. Use lean

   Pipe targeted planning of tooling racks that match customary procedures can effectively avoid such problems, and the wiring harness project can be repeatedly disassembled and used when it is updated.

   2) Planning is sensitive. It can be satisfied with any creative planning and idea, and transform it into a personalized structure suitable for practical application. Choosing different types of tooling racks for lean tube planning can sensitively satisfy the requirements of tooling racks for various wiring harness planning. The production and assembly process is extremely simple and agile. The lean tube planning tooling frame is selected, and no special professional skills are required, and the production can be made through simple processing training. It can also quickly produce and satisfy the batch production of supporting tooling equipment invested in the early stage, and shorten the production cycle.

  3) Easy to reuse. Because the lean tube is connected by the method of matching and fastening the tube and the tube buckle, it can be flexibly disassembled and assembled from scratch when the project is updated and the tooling frame is updated to satisfy the assembly process of different use structures.

   (3) When choosing lean management, pay attention to the following points

   1) Lean management. Because the lean tube uses a hollow structure plan, there are limitations in the connection between the tube and the tube, which determines that the tooling rack made by the lean tube plan cannot be effectively satisfied with the high-quality storage plan. On the premise of satisfying the requirements of the wire harness manufacturing process, the load-bearing problem of the supporting tooling of the lean pipe needs to be paid special attention in the early stage of the planning and avoided by adding reinforcing ribs.

   2) Lean tube wear. Because of the convenience of repeated use of lean tubes, it is unavoidable that they often disassemble and assemble supporting tooling for different process requirements. This also shows the phenomenon of different degrees of wear and rust on the inner wall of the lean tube. Affect the appearance and usefulness of tooling for new processes.

  2, aluminum profile

  Aluminum profile is developed and manufactured according to the existing planning needs. It is the most extensive type of non-ferrous metal structure material in the wire harness manufacturing industry. It has been used in many processing occupations such as automobile manufacturing and wire harness manufacturing.

   (1) Selection of aluminum profile in wire harness manufacturing industry

  In the process of wire harness processing, we can plan for special characteristics of wire harness products, and choose the supporting tooling rack made by aluminum profile planning. Now the wire harness crimping process, which is mainly used in the wire harness processing process, is shown in Figure 5. For the wire crimping process in the wire harness processing process, the crimping machine itself is of high quality and frequently vibrates. Choose aluminum profiles to plan targeted tooling The frame can not only satisfy the load bearing problem of the crimping machine, but also deal with the frequent vibration of the crimping machine when it is working. The wire harness wrapping process is shown in Figure 6. For the punching wire wrapping process in the wire harness processing process, the wrapping machine itself is of high quality, and the electrical circuit needs to be arranged on the tooling rack. The choice of aluminum profile can effectively satisfy its own load-bearing and electrical The circuit is arranged and routed in the aluminum profile. The wiring harness inspection process is shown in Figure 7. Because the inspection process tooling method is single and the curing effect is significant, the aluminum profile is used to plan the wiring harness inspection process tooling frame, which facilitates the wiring of the electrical circuit and satisfies the curing of the inspection process orientation.

   (2) The selection of aluminum profiles has the following characteristics

  1) Corrosion resistance. The density of aluminum profile is only 2.7g/cm3. In most environmental conditions, including air, water (or salt water), petrochemical and many chemical systems, aluminum profiles can show corrosion resistance.

   2) Non-ferromagnetic. Aluminum profile is non-ferromagnetic, which is an important feature for wire harness manufacturing.

  3) Machinability. The machinability of aluminum profiles is feasible. In various deformed aluminum alloys and cast aluminum alloys, and in various states after these alloys are produced, the machinability characteristics change considerably, which requires special Machine tools or skills. The specific tensile strength, yield strength, ductility and corresponding work hardening rate dominate the change of allowable deformation.

   (3) Please pay attention to the following points when choosing aluminum profiles

   The cost is expensive, which directly adds to the cost of wire harness manufacturing and processing supporting tooling, which restricts the cost of using aluminum profiles to plan wire harness processing and mounting. Moreover, when using aluminum profiles to plan and make wire harness tooling racks, the production of aluminum profiles is messy, because aluminum profiles need to be deep-processed through special machine tools and skills. When planning aluminum profile wire harness production supporting tooling, it is necessary to fully consider the feasibility of aluminum profiles. The interchangeability with later projects.

  3, square steel pipe

   Square steel pipe is a multi-standard, square hollow profile steel structure material. Its surface is coated or over-plasticized to prevent oxidation of the internal profile steel. In general, square steel pipes of different standards and thicknesses are used for welding to make various material racks and workbenches (tables). It is necessary to pass sample verification and ergonomic analysis before mass production.

   (1) Selection of square steel tube in wire harness manufacturing industry

   In the process of wire harness processing, it is possible to select a matching tooling frame planned and produced by square steel pipes for the relatively stable and versatile procedures in the wire harness processing. Nowadays, the wire harness storage process, which is mainly used in the wire harness processing process, is shown in Figure 8. The square steel itself is welded, and the quality of the goods carried is far greater than other profiles, which can effectively prevent the tooling rack from being too large due to the load. The resulting deformation and collapse of the tooling frame pose a safety hazard. The matching process of the wire harness equipment is shown in Figure 9. When the load is satisfied, the reusability and stability can be effectively ensured. The wiring harness buffering process is shown in Figure 10, which can satisfy the convenience of storing different materials on the same tooling rack.

   (2) The selection of square steel pipe has the following characteristics

  1) Square steel has strong hardness. This is also the primary condition for the selection of the square steel pipe profile in the wire harness production process. It has good compressive strength and bending strength in the load-bearing process. In the planning and production of the wire harness processing process, it can give priority to the process that needs special consideration in the load-bearing flanging Use square steel to plan.

   2) Square steel has good stability. Due to its own quality, it is not easy to be offset by external force collision after positioning and use. Therefore, when planning the wire harness processing tooling frame for the square steel profile, we can fix it. Square steel profiles are preferred for reusing processes to plan supporting tooling frames.

   (3) When choosing square steel pipes, pay attention to the following points

1) The processing of square steel pipe profiles requires one-time welding and refurbishment according to the planning drawings. Therefore, when using square steel profiles to plan and produce the supporting tooling racks for each process of wire harness processing, the tooling planners need to fully consider in the early planning. , Repeatedly verify the feasibility of the tooling rack to prevent problems such as processing rework and unreasonable practical application caused by imperfect pre-planning.

2) After the reprocessing of the square steel tube profile is completed, it is not convenient to move, because the quality of the square steel profile itself is too large, and it is not convenient to move personnel. Therefore, in the early stage of planning and positioning, the on-site planner is required to choose the tooling planned by the square steel. The frame is accurately delineated to prevent the repeated movement of the square steel frame caused by the change of the site plan in the later period.

To sum up, with the development of automobile wiring harness production skills, the supporting tooling equipment for various new data planning and production is gradually used at the production site. On-site planning and planning engineers must be proficient in the functions and performance parameters of the supporting tooling equipment for each process. , Make full use of the existing resources of supporting tooling equipment, and maximize the utilization rate of supporting tooling equipment. Reasonably select existing data to plan and produce supporting tooling equipment to provide the greatest convenience and usefulness for the production and processing of wire harnesses. In view of the many processes in the wire harness processing profession and the different planning requirements for each process, the planners of the wire harness tooling racks need to select different materials to plan and produce the tooling racks that match each process.