There are three reasons for this: First, the quality of the harness raw materials and cables is not up to standard, the flexibility is not enough, or the wire diameter is not enough; Second, when the wire harness is being cut, the wire feeding roller presses the wire too tightly, causing the wire core to break; Third, when crimping the terminal of the harness, the machine is adjusted too tightly, and the downward pressure of the blade is too large, causing the core wire to break.

When the wire harness is welded and processed, if the wire core does not have enough tin, or the contact surface of the two wire cores is too small, false soldering will occur. As the welding point is covered with insulating sleeve, the appearance cannot be seen. Some problems can be found in the quality inspection process. If the wire harness is installed on the equipment, it will be prone to failure.

a. The tightness of the protective layer outside the harness must be the same;

b. The harness terminal shall be installed in place in the sheath and shall not be detached;

c. The insulation layer on the surface of harness contact shall be good, and the conductor shall not have indentation;

d. The harness must be assembled correctly without dislocation or leakage

Wires can be divided into electronic wires and cable wires according to their properties: Electronic wires include unshielded wires and shielded wires (UL1571 wires have shielded wires, and other electronic wires are generally unshielded wires);

Cable wires also include unshielded wires and shielded wires, such as UL2464, which can be divided into these two types.

According to standards: UL/CSA (safety regulation line), CCC (national standard line), VDE (German standard line), PSE (daily standard line), etc

The raw materials of automobile wire harness include the main materials and auxiliary materials that constitute the wire harness. The main materials include wire terminals, sheaths, fuse boxes, and the auxiliary materials include rubber parts, waterproof bolts, adhesive tapes, PVC pipes, corrugated pipes, industrial plastic cloth, insurance sheets, relays, ties, buckles, brackets, diodes, etc.

By understanding the use of electronic harnesses, we can better understand the cost of customized harnesses in different industries. For example, the customization cost of electronic harnesses in the medical industry is higher.

Customized electronic harnesses require more rigorous testing to ensure functionality, and because the material requirements are more durable, there is less need to replace the ordered components, which can effectively reduce the overall cost.

To judge the quality of the connecting wire, we should not only look at the appearance size, but also the thickness of the copper core inside. Because some connecting wires are made of extremely thick rubber while the copper core is very thin, it is mainly determined by the size of the copper core cutting section.