Harness processing is a relatively high-skill occupation, which has the following ten skill indicators requirements in production.

1. Appearance requirements

After the wire harness is processed, the surface should be lubricated, the skin should be uniform, no pores, cracks, indentation, bumps, damage, mottling, dirt, etc.

The wiring harness is crimped firmly with the terminal without loosening. If the terminal is welded, it should be welded strong without loose core.

2. Skill requirements

The insulation should be tightly packed on the conductor, should be simply peeled off without damaging the insulator, conductor tinned layer. The surface of the insulation should be flat uniform in color.

The average value of the insulation thickness should be less than the nominal value of the rule, the thickness of the thinnest point should be less than 90% -0.1mm of the nominal value. The thickness measurement results shall be rounded to one decimal place in accordance with GB1.1 Appendix C (Compensation Parts).

The insulated wire core should be able to taste the communication of 50Hz spark test of GB3048.9-83 rules as a center view.

3. Separation of insulated cores

Insulated wire cores should be color-selected with colors that are easy to recognize hard to erase, should conform to the rules of the wire cable marking method. If necessary, other identification methods are allowed, but they should be regulated in the product specifications. The preferred colors color sequences are as follows:

a) Single-core cable: no preferred color;

b) Two-core cable: no preferred color;

c) Three-core cable: green / yellow color, light blue, brown; light blue, black, brown;

d) Four-core cable: green / yellow bicolor, light blue, black, brown; light blue, black, brown, black brown;

e) Five-core cable: green / yellow bicolor, light blue, black, brown, black brown; light blue, black, brown, black brown, black brown.

f) The green / yellow color is the color of the grounding core. When there are green / yellow grounding wires in the insulated wire of the cable, other insulated cores are allowed to use green yellow.

4, sheath

The sheath should be tightly packed on the stranded insulated core inner sheath, should be simply peeled off without damaging the insulator inner sheath. The jacket should be flat uniform in color. The average thickness of the sheath should be less than the regular nominal value, the thickness of the thinnest point should be less than 85% (0.1mm) of the nominal value.

The thickness measurement results shall be rounded to one decimal place in accordance with GB1.1 Appendix C (Compensation Parts).

5. Mechanical strength

The crimped part should be able to withstand the mechanical stress that may appear during normal use. Whether it is qualified , maybe check through the following tensile strength experiment.

Apply the pull force specified in Table 2 Table 1 for 1 min. When applying force, the explosive force should be used. This tensile force can also be applied by a tensile testing machine. The moving speed of the head of the testing machine should be between 25㎜ (1.0in) / min to 50㎜ (2.0in) / min, there should be no drop cracking.

The wire should be thoroughly burned, the flame on the surface of the sample should calm down by itself after the test. The distance between the scorched affected part the lower edge of the fixture on the experimental device should be less than 50mm.

The wire should be able to withstand the 50 Hz non-immersed voltage test of the communication in the following table 2 rules, the 50 Hz non-immersed voltage test of the communication in the table 4 rules between the insulated cores of two-core above round sheathed wires.

6. Insulation resistance

The insulation resistance of the wire should be tested according to the rules in Table 5 on the insulated core after the expression 4 rule voltage test.

7, the electric strength of the wire

The voltage is applied in turn between all other conductors connected together in each conductor pair, then the voltage is applied between all conductors sheaths connected together:

a) Weak wire harness: 1500V communication voltage, continue for 1min;

b) Strong wire harness: 2000V communication voltage, continue for 1min;

c) Sheath: 3750V communication voltage, continue for 1min;

When the above voltage is applied, there will be no crossover flashover.

8. The appearance quality of the flat fast connection end on the harness

a. The appearance of the terminal should have an outstanding appearance, without scratches, burrs, significant deformation, poor plating.

b. There must be no damage, looseness drop at the riveting.

9, Flat quick connection ends are grouped according to the nominal width of the insert

Ends within the scope of this specification include the following groups:

——2.8mm (0.110in) series;

——4.8mm (0.187in) series;

——6.3mm (0.250in) series.

Note: As long as it does affect the regular scale meet the experimental requirements, the shape of each part of the tip can be different the shape shown in the specification, for example: there can be corrugated inserts, folded inserts, etc.

10. The preferred cross-sectional area of the wire should be 0.5㎟, 0.75㎟, 1.0㎟, 1.5㎟, 2.5㎟, 4.0㎟ 6.0㎟, the corresponding AWG wire gauge.