New Energy Wire Harness plays a vital role in new energy vehicles and other fields, and the key links of its production process directly affect the quality and performance of the wire harness.
First of all, the selection of raw materials is one of the key links. New Energy Wire Harness needs to use high-quality wires, insulation materials, connectors, etc. The wires should have good conductivity and flexibility, and be able to withstand high currents and frequent bending. The insulation materials must have excellent insulation performance, high temperature resistance and aging resistance to ensure the safe operation of the wire harness in various complex environments. The connector needs to have reliable connection performance and good sealing to prevent poor contact and leakage.
Secondly, the design and layout of the wire harness are crucial. In the design stage, it is necessary to reasonably plan the direction, length and branching of the wire harness according to the requirements of the new energy system to reduce the length and weight of the wire harness and improve the efficiency and reliability of the system. At the same time, the heat dissipation of the wire harness should be considered to avoid affecting the performance and life of the wire harness due to local overheating. In terms of layout, it is necessary to ensure that there is enough clearance between the wire harness and other components to avoid friction and collision, and to facilitate installation and maintenance.
Next, the processing and manufacturing links are also key. Including cutting, stripping, crimping of wires, set of insulating sleeves, and assembly of connectors. These processes require the use of high-precision equipment and tools to ensure the accuracy and consistency of processing dimensions. For example, the crimping of wires must ensure that the crimping force is moderate, the contact resistance is small, and the connection is firm and reliable. At the same time, the quality of the processing process must be strictly controlled, and strict inspection and testing must be carried out to promptly discover and eliminate unqualified products.
Then, the testing link of the wire harness is indispensable. Including electrical performance testing, insulation performance testing, and withstand voltage testing. Through these tests, it can be ensured that the wire harness has good conductivity, reliable insulation, and can withstand the specified voltage and current without failure. At the same time, environmental adaptability tests can also be carried out, such as tests under high temperature, low temperature, humidity, vibration and other conditions to verify the performance and reliability of the wire harness in different environments.
Finally, the packaging and transportation links also need to be taken seriously. Appropriate packaging materials and methods should be used to protect the wire harness from damage during transportation. At the same time, attention should be paid to the storage environment to prevent the wire harness from being damp, heated, corroded, etc.
In short, the production process of New Energy Wire Harness involves multiple key links, from raw material selection to design layout, processing and manufacturing, testing, and packaging and transportation. Each link requires strict quality control to ensure the performance and reliability of the wire harness and meet the application needs in the new energy field.