The assembly process of the electronic wiring harness must be performed very carefully, because any defects in the production assembly process will cause the overall product to fail, resulting in accidents. Although manufacturers all know the seriousness, they still make some common mistakes when producing assembly harnesses. The following is a list of 6 common mistakes made by wire harness manufacturers in the production and assembly of electronic wire harnesses.


Electronic wiring harness
1. Prepare the wires
Wire preparation must be performed with care and precision, because it determines the overall efficiency and performance of the component. Many manufacturers made mistakes in this first stage and chose the wrong wire, which was cut and stripped at the end.

2. Do not follow the assembly drawing
   Failure to follow the assembly drawings can cause many problems when connecting the wires in the chassis. Harness manufacturers often incorrectly connect the wires, which leads to the failure of the wire assembly, which in turn leads to the failure of the entire system. error.

3. Defects in crimping
    The crimping process involves wiring the end of the harness into the harness. This is the most critical step in the harness assembly. If not performed properly, it will cause an open circuit or short circuit. If many manufacturers do this arbitrarily, it will cause a product malfunction.

4. Incorrect welding
    Incorrect welding This is another major area where manufacturers make mistakes. Improper welding of wires and terminals can cause thermal damage. When performing this operation, please use the correct welding equipment and the correct welding temperature.

5. Missing wires and using wrong hardware
    To meet the project schedule, some wire harness manufacturers may tend to ignore wires that are critical in assembly. This may cause failure of the harness assembly. In addition, the manufacturer may use the wrong hardware, including brackets, clamps, washers or screws to assemble the harness.

6. Incorrect wire connection
   The final step in the wire harness assembly process is to use plastic straps to bundle the wires. Sometimes, the wire harness manufacturer will tighten the package so that the wire is damaged. On the other hand, if it is loose, it may not be possible to hold the bundle properly, so the manufacturer must ensure that the tie is tightened around the wire in the correct manner.

    If the above errors can be avoided and other assembly specifications are taken into consideration, the harness manufacturer can assemble the harness according to the customer's requirements, and the double inspection process helps eliminate the above defects and produce a high-quality harness.

After reading the above, I believe everyone should understand the 6 common mistakes in the production and assembly of electronic wire harnesses.