OEM ODM Air Conditioner Wiring Harness Molded Compressor Plug Harness Manufacturers ​

 


 

Connector Types for Cable Assembly and Wiring Harness
Terminal Blocks
Butt Connectors
Spade Connectors
Ring Connectors
Bullet Connectors
DIN Connectors
MIL-Spec Connectors
M8 and M12 Connectors
D-Sub Connectors
IDC Connectors
Molex Connectors
BNC Connectors
SMA Connectors
USB Connectors
RJ45 Connectors
HDMI Connectors
Anderson Powerpole Connectors
Deutsch Connectors
Weather Pack Connectors
XLR Connectors
 
This flowchart can help illustrate the step-by-step procedure followed in the manufacturing of wiring harnesses:
 
1. Design and Engineering Phase:
 
Requirement Gathering: Understand the specifications and requirements of the wiring harness.
Design: Create the wiring harness design using CAD software.
Prototype Development: Develop a prototype based on the design specifications.
Design Verification: Test and validate the design to ensure it meets all requirements.
 
2. Material Procurement:
 
Component Selection: Select appropriate connectors, terminals, wires, and other components.
Supplier Sourcing: Identify and source materials from approved suppliers.
Quality Check: Inspect materials for quality assurance before production.
 
3. Wire Cutting and Stripping:
 
Cutting: Cut wires to the required lengths.
Stripping: Strip the insulation from the ends of the wires as needed.
Quality Inspection: Check the cut and stripped wires for any defects.
 
4. Terminal Crimping:
 
Crimping Process: Attach terminals to the stripped ends of the wires.
Crimp Inspection: Inspect the crimped terminals for proper attachment and strength.
5. Assembly:
 
Connector Assembly: Insert the crimped wires into the designated connectors.
Harness Routing: Arrange the wires according to the design layout.
Taping/Sheathing: Apply protective sheathing or tape to bundle and protect the wires.
Quality Inspection: Inspect the assembled harness for proper configuration and quality.
 
6. Overmolding (if applicable):
 
Mold Setup: Prepare the mold for the overmolding process.
Injection Molding: Apply overmold to the required sections of the harness.
Cooling: Allow the overmolded harness to cool and solidify.
Quality Check: Inspect the overmolded harness for defects and consistency.
7. Testing and Quality Assurance:
 
Electrical Testing: Test the harness for continuity, insulation resistance, and electrical performance.
Visual Inspection: Check for any visual defects in the final harness.
Functional Testing: Ensure that the harness meets all functional requirements.
 
8. Packaging and Labeling:
 
Packaging: Package the wiring harness according to customer specifications.
Labeling: Apply labels with necessary information (e.g., part number, batch number).
Final Inspection: Conduct a final quality check before shipping.
 
9. Shipping:
 
Logistics: Arrange for the transportation of the finished wiring harnesses to the customer.
This flowchart provides a high-level overview of the wiring harness production process. Each of these steps can be further detailed depending on the specific requirements and complexity of the harness being manufactured.
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