1. Prepare the wires
Careful preparation of wires is necessary as it determines the overall efficiency and performance of the components. Many manufacturers make mistakes at this stage by selecting the wrong wires, which are cut and stripped at the ends.
2. Not following the assembly drawing
Not following the assembly diagram can lead to many problems when connecting wires in the chassis. Wiring harness manufacturers often make mistakes in connecting wires, which can cause wire components to fail and ultimately lead to system failure. It is necessary to strictly follow the assembly diagram to avoid such errors.
3. Defects in crimping
The crimping process involves terminating the wire harness into the wire harness, which is a critical step in the wiring harness assembly. Improper execution can result in open or short circuits. If many manufacturers randomly perform this operation, it can lead to product malfunctions.
4. Incorrect welding
Incorrect welding is another major area where manufacturers make mistakes. Improper welding of wires and terminals can lead to thermal damage. When performing this operation, please use the correct welding equipment and welding temperature.
5. Lack of wires and incorrect use of hardware
In order to meet the project schedule, some harness manufacturers may tend to overlook the crucial wires in assembly. This may cause malfunctions in the wiring harness components, and in addition, manufacturers may use incorrect hardware, including brackets, fixtures, washers, or screws, to assemble the wiring harness.
6. Incorrect wire connections
The final step in the wiring harness assembly process is to use plastic straps to tie the wires. Sometimes, the wiring harness manufacturer may wrap the wires too tightly, resulting in damage to the wires. On the other hand, if it is loose, it may not be possible to grip the bundle correctly, so manufacturers must ensure that the tie wraps are fastened around the wires in the correct way.