Process content：
For the wire harness of sensors, the main harness shall not be cut and rewired.
When the harness is too short and a wire connection is needed, flush cutting to the wire harness must be avoided. We should make the two harness joints differ by about 30mm, and make sure the conductor crimping would not break, to have the cross-section of the joints meet the quality requirements. After the connection, we have insulation tape wrapped.
When re-crimping is needed due to plugs are not well firmed, the terminals should be pressed separately on the conductor and insulation layer. When the re-crimping is finished, crimping the wire the conductor should not interfere with plugging. The crimping connected terminal and the crimping point’s cross-section should meet the quality requirements.
The wires and the counter wires for connection should be of the same diameter and color.
Process parameters:
(1) The difference between the wire harness joints is about 30mm
(2) The length of the branch wire should be more than 30mm.
(3) Between the joints, joints and branch points, the distance should be more than 20mm.
(4) The wire and terminal connections need to be installed with an insulation sleeve, the insulation sleeve length shall be more than 20mm.
Quality requirements
Terminals and wire conductor crimp and crimp joints at the cross-section should meet the following requirements:
(1) All the single wires’ cross-sections in the conductor should be irregular polygons. There should be no obvious gaps between conductors and terminal contact parts, and between single wires. Crimp parts should be fully wrapped around all conductors. The terminal crimp curl part a and b must be connected and symmetrical.
(2) The distance (d) from curl parts a and b to the bottom should be more than 1/2 of the nominal diameter of the single wire.
(3) For burrs on both sides of the cross-section bottom, the height should not exceed the thickness of the terminal (g).
(4) There should be no gaps between the terminal curl part a and b. The end part can not be connected with other parts, cross-sectional terminal crimping parts can not appear cracks.
(5)Complete tap wrapping is required. Tape wrapping thickness should be appropriate, safe, reliable and looks nice