Dongguan Baori Electronics Co., Ltd. strictly adheres to industry standards in the wire harness manufacturing process, combining advanced technology and rich experience to produce high-quality products. The entire manufacturing process varies depending on the design, ranging from simple to complex. The following are some common steps:

Throughout these processes, the use of automated machinery is limited, with greater reliance on skilled technicians' manual operations to ensure the quality and reliability of the wire harnesses.

Design

As with other electronic manufacturing processes, the production of wire harnesses always begins with appropriate design. The design varies according to different application scenarios. For example, in the automotive field, wire harnesses must meet the environmental requirements of high temperatures, humidity, and frequent vibrations in the engine compartment; in flat panel displays, wire harnesses need to adapt to the precise wiring requirements within confined spaces. Therefore, custom design is one of the challenging aspects of the wire harness manufacturing process.

At this stage, engineers need to consider multiple factors comprehensively. First, they must determine the specifications, quantity, and layout of the wires in the wire harness based on the electrical performance requirements of the equipment. Second, they need to address potential performance issues that the wire harness may encounter during regular operation, such as electromagnetic interference and signal attenuation. Additionally, they need to determine the components and make decisions on components, materials, and other aspects, such as selecting suitable connectors and insulation materials.

Sample Production

By producing samples, engineers can intuitively understand how the wire harness works in a real environment, identify potential design problems, and make timely adjustments. After the sample production is completed, engineers will conduct various tests on the samples, such as electrical performance tests and mechanical performance tests, to verify the rationality and feasibility of the design. Based on the test results, the design is optimized and improved to ensure the quality of the final product.

Production and Assembly

Unlike other electronic manufacturing processes, the wire harness manufacturing process is largely manual. This is because wire harnesses need to be highly customized to meet the needs of different equipment and applications. Manual assembly helps solve various professional problems involved in the manufacturing process of some complex products.

(I) Wire Cutting

In this step, a wire cutting machine is used to cut the wires to the required length. The wire cutting machine can precisely control the cutting length to ensure the dimensional accuracy of the wires. At the same time, to ensure that the cut ends of the wires are neat after cutting, facilitating subsequent stripping and connection operations, the cutting machine is usually equipped with sharp blades and a stable cutting platform.

(II) Stripping and Connection

In this step, the outer sheath of the wire is stripped to install connector modules, housings, or terminals. The stripping operation requires the use of professional stripping tools. Based on the specifications of the wires and the thickness of the insulation materials, the stripping length and depth are adjusted to avoid damaging the internal conductors.

After stripping, the connector modules, housings, or terminals are installed on the wires. This requires the use of crimping machines or welding equipment to ensure a firm and reliable connection. During the connection process, pay attention to the polarity and direction of the wires to avoid device failures caused by incorrect connections.

(III)  Assembly

In this step, a wiring board is used to assemble the wires into a wire harness. A wiring board is a tool used to fix and arrange the wires. It can help workers arrange the wires neatly according to the design requirements and perform necessary binding and fixing.

During the assembly process, pay attention to the direction and spacing of the wires to avoid entanglement or friction between the wires, which may affect signal transmission and equipment heat dissipation. At the same time, install various protective devices as required by the design, such as heat shrink tubing and insulating tape, to improve the safety and reliability of the wire harness.

(IV) Testing

Safety testing is an important part of any electronic manufacturing project. At this stage, the wire harness undergoes strict testing to verify its practicality and durability in actual environments. The test content includes electrical performance tests, mechanical performance tests, and environmental adaptability tests. Electrical performance tests mainly detect indicators such as conductivity, insulation resistance, and withstand voltage of the wire harness to ensure compliance with design requirements. Mechanical performance tests detect the tensile strength and bending performance of the wire harness to ensure that it will not be damaged by external forces during use. Environmental adaptability tests place the wire harness under different environmental conditions, such as high temperature, low temperature, and humidity, to check the stability of its performance. Only wire harnesses that pass all test items can be considered qualified products and enter the next process or be delivered to customers.

If you have custom requirements for wire harnesses, welcome to contact Dongguan Baori Electronics Co., Ltd. We have a professional technical team and advanced equipment and will wholeheartedly provide you with high-quality wire harness products and services. We will reply to your inquiries as soon as possible and look forward to cooperating with you hand in hand to create a better future.