Tài liệu đào tạo về dây điện wiring harness

TRAINING MATERIAL FOR TRAINEES TÀI LIỆU ĐÀO TẠO CHO HỌC VIÊN ABOUT 5S 1.Seiri (Sifting): Arrange,classify necessary and unnecessary things,and dismiss unnecessary things 2.Seiton (Sorting): Sorting all things that had been already sifted,put things in the right place and stick their names Wherever everyone can also take and use it without spending time for finding 3.Seisou (Shining): Make clean (garbarge and dust) around and at the working place 4.Seiketsu (Standardizing): Keep and maintain clean state around and at our working place Everyone is also satisfied when seeing 5.Shitsuke (Sustaining): Obey regulations of the factory.In addition,you must obey4S (sifting,sorting,shining,standardizing) VỀ 5S 1.Seiri (Sifting): Sắp xếp, phân loại thứ cần thiết không cần thiết, loại bỏ thứ không cần thiết 2.Seiton (Sắp xếp): Sắp xếp tất thứ được sàng lọc, đặt thứ vào chỗ dính bảng tên chúng Bất nơi người lấy sử dụng mà khơng cần thời gian cho việc tìm kiếm 3.Seisou (Shining): Làm khu vực xung quanh nơi làm việc 4.Seiketsu (Standardizing): Giữ gìn trì trạng thái xung quanh nơi làm việc Để tất người thấy hài lòng, thoải mái nhìn thấy 5.Shitsuke (Sustaining): Ln tn theo quy định nhà máy Ngoài ra, bạn phải thực 4s trên) WHAT IS WIRE HARNESS (WH)? What is Wire Harness ? Wire Harness for Automobile Definition : Wire Harness is a product on which components are fitted (those components are used to protect electric wire and fit into car) It is very necessary for car (Wire Harness for automobile) • Function of W/H Function : transmit exactly signal/ electrical energy to electric equipment of cassis / engine in car WIRE HARNESS LÀ GÌ (WH)? Wire Harness ? Wire Harness cho ô tô Định nghĩa: Dây dẫn dây sản phẩm mà thành phần trang bị (những thành phần sử dụng để bảo vệ dây điện phù hợp với xe) Nó cần thiết cho xe (Wire Harness cho tơ) • Chức W/H Chức : Truyền xác tín hiệu / cơng suất vào thiết bị điện khung gầm / động xe WHAT IS WIRE HARNESS (WH)? Basic component parts of Wire Harness: a Wire: b Terminal: c Housing: d Clamp: e Grommet: f Protector: g Many another parts: WIRE HARNESS LÀ GÌ (WH)? Thành phần Wire Harness: a Dây: b Terminal: c Housing: d Clamp: e Grommet: f Bảo vệ: g Nhiều thành phần khác: WHAT IS WIRE HARNESS (WH)? Steps produce Wire Harness: Wire: Stripping Terminal crimping Sub assy (inserting terminal into housing) Connector Sub Assembling Completed product WIRE HARNESS LÀ GÌ (WH)? Các bước tạo Wire Harness: Dây: Tuốt Dập Terminal Sub assy (Lắp terminal vào housing) Vật kết nối Sub Lắp ráp Sản phẩm hoàn thành KNOWLEDGE ABOUT ELECTRIC WIRE Because of improving ring mark of wire to save cost price to Các loại AVSS 0.3 & 0.85 sq,0.5 & 1.25 sq thay đổi vòng đai Ring color Silver Blue or Brown Silver Silver Orange or White (nearly light brown) KNOWLEDGE ABOUT ELECTRIC WIRE g Shield: Definition: Is electric wire applied with metallic layer (conduction material like copper,aluminum and so on) surrounding the wire for protecting circuit from electromagnetic induction or static-electricity induction Kind Struction Explanation Vertical shield Shield wire in which having shield surrounding core wire Kind of slver-plated on shield and kind of unplated Shield net Shield wire in which having shields are knitted to each other and is covered electric wire Kind of silver-plated on shield surrounding core wire and kind of unplated Foil Shield (doren wire) Shield wire in which have doren wire and zine paper doren surrounding As to metal paper layer,use copper paper for engine room,auluminum paper layer for inside part (it is plated by tin to prevent from frictimal wear Knowledge of terminal & crimping Female terminal & Male terminal KNOWLEDGE ABOUT ELECTRIC WIRE There are kinds of terminal: A End Terminal: (F: female) (M: male) * Is the combination between beginning part this terminal to the end of terminal * Kinds of end terminal: gold-plated,silver, tin,aluminum-plated B Side terminal: (F: female) (M: male) * It is linked by carrier ( Must have bur) * Kind of side terminal: gold-plated,silver,tin, aluminum-plated There are kinds of terminal: * (M: Male) * (F: Female) Uncrimped-terminal has basic parts * Mating part * Wire Barrel * Insulation Barrel Crimped-terminal has basic parts * Mating part * C/H (Crimp Height) * I/H (Insulation Height) Crimped-terminal is divided into main kinds * Water-resistant terminal (terminal that has rubber plug) * Water-unresistant terminal (terminal that doesn’t have rubber plug) Water-unresistant terminal Water-resiatant terminal KNOWLEDGE ABOUT ELECTRIC WIRE Gold,silver,tin-plate: * Side terminal: only plate a part of mating part * End terminal: plate all parts of terminal Crimping terminal method: * Sample crimping and visual check (QC check) * Measure C/H,I/H,C/W value (C/W value is only taken when there is special terminal) * Measure bend value of terminal (for M terminal) * Check crimping strength (check pulling force) * Mass crimping Examples are classified by size of terminal KNOWLEDGE ABOUT ELECTRIC WIRE Name Funetion Tanshi Circle shape terminal,is used to fit crew into frame,engine It almost use at earth part Tanhi meter Is used to fit into Flexible Print Connector Almost it is fited at measure unit Tanshi PB This terminal is called positive lock terminal or plate.Its funtion is to combine with plug and is used for some part: Packing Brake switch,near deforger,cigar lighter Waterresistant Terminal Prevent water absording inside by fit rubber plug into terminal: is fited into external part Tanshi Fuse Terminal is used to fit fuse as it name Tanshi joint It is used to joint wire when dividing circuit Tanshi battery It is used at the battery,alternator,engine earth Earth Tanshi La Example KNOWLEDGE ABOUT ELECTRIC WIRE No Name Funetion Wire Barrel It covers elecric wire part.It funtion is to conduct electricity between terminal and wire,it is very imprtant so that the operator must pay attention to this job Serration Is slotted on the wire Barrel Insulation Barrel It function is to hold electric wire of wire barrel and keep safety from impacting Mating part Is the contact par with terminal Spring tongue It function is to push tab part of male terminal down when combine to each other Lance hold When inserting terminal into housing,emerged part is kept inside of housing The position for lance located in lance hold Lance It is used as a lock part so that the terminal won’t slip out after having been inserting into housing Transition Is a joint part between mating part and wire barrel Tab gap Is a hole on female terminal,Is the position to hole the mating part of male terminal This position is very important to keep good conduction 10 Mating part Is a flat part at the head of terminal 11 Shoulder It is used to stabilize terminal after being crimped into electrical wire KNOWLEDGE ABOUT ELECTRIC WIRE Numb er Name Crimp Height (C/H) Funetion Is the value of height of core wire-crimped position,Its function is to link terminal into electric wire.ro get good condition of electric current,each kind of terminal and wire we have each different specification which must be managed closely Insulation Height (I/H) Is covering shealth part.It must keep insulation tight so that core wire won’t be damaged Post Bell-Mouth To prevent core wire from being scratched by wire barrel All terminal must have post-bell mouth to prevent from breaking core wire Front Bell-Mouth To prevent terminal from being deformed Post OFF tab Front OFF tab Is the remaining part on terminal after cutting terminals.Its length is about 0~0.5mm in order to be easy in detecting wrong when insert terminal or open barrel Core wire protruding length Is the length from wire barrel’s edge to the end of core wire protruding.It is set up to prevent wrong inserting.Its length is about 0~1.0mm Insulation (vinyl) Is set up to prevent core wire lowering or insulation beating.Insulation must be between wire barrel and insulation barrel KNOWLEDGE ABOUT ELECTRIC WIRE Correct terminal: o Front side of terminal is called “terminal’belly” * Mating part isn’t deformed,abnormal,twisted * Must have front bellmouth and post bellmouth’s core wire protruding (core wire protruding length is about 0.5mm ~ 1.0mm.) * Must have up bellmouth and low bellmouth (except some special terminals) * Insulation protruding length: “terminal without rubber plug”0.5mm”terminal with rubber plug” * C/H: hold core wire,I/H: hold insulation * Bell function: protect core wire when crimping terminal into electric wire (prevent from breaking core wire) o Backside of terminal is called “terminal’s back” It isn’t deformed, abnormal,scratched,off tab protruding is 0~0.5mm * kind of terminals : water-resistant terminal (terminal that has rubber plug) Water unresistant terminal (terminal that doesn’t have rubber plug) * Function of rubber plug is to prevent water When inserting rubber plug into electric wire,the distance from end of insulation to end rubber plug is 1.0mm Position of rubber plug (OK) Core wire is bitten (NG) KNOWLEDGE ABOUT ELECTRIC WIRE Judgment standard for crimping terminal state: Priod for check Inspection items Crimp ing condi tion Mass opera tion O O O O Size of core wire protruding is correct or not? O O Bell mouth has back or not? O O Barrel have deform or not? O O Cut off tab is correct or not? O O Whether having bur or not? O O Whether having scratch on back’s terminal or not? O O The position to fit rubber plug is correct or not? (At the place of barrel can check core wire,sheath and rubber plug) O O Rubber plug is broken,scratched or not? O O Are core wire breaking,no core wire,core wire bitting or core wire drawing out? The position of sheath is correct or not? (Position of shesth is distance between barrel) Crimping state State of rubber plug (only use for water resistant Unsuitable items Terminal are bending up,bending KNOWLEDGE ABOUT ELECTRIC WIRE Wrong cases: KIẾN THỨC VỀ DÂY ĐIỆN Trường hợp sai: KNOWLEDGE ABOUT ELECTRIC WIRE Three main management items of crimping operation: Training material for trainess Visual management,pulling force management,Crimp Height management are three main management items of crimping operation.Base on the crimping quality management need to analyze enough important idea of each item 1) Why you need to manage Crimp Height? Is the best important management item when you are crimping.Electric current is passed through the wire,transmitted from this terminal to that terminal and connect with circuits.Role of crimp is connecting terminal with electric wire.If it isn’t crimping at stipulated height,so electric current won’t pass to terminal or breakdown by outside force.We must to obey operation principles,because Crimp Height is set up to ensure for best crimping ability.If it passed allowable tolerance,it’ll occur damage such as engine isn’t run or serious case are burning calmp and car by heating.In addition,its also damage for man.We are sale Wire Herness and guarantee quality for customer at the same time Touching electric circuit Heating Breakdown Damage for man 2) Why you need to manage pulling force? Crimp Height determine pulling force.Quality management section of production technology department is marking enough experiments for pulling force,taking Crimp Height in the best condition to make standard value.In the cases can’t discover when the knife is worn or blade is fitted incorrect with Crimp Height.This is the reason to confirm pulling force crimping The crimp is playing an important role.If Crimp Height management and pulling force management are checking carefully on the electric wire,so they aren’t any problem for crimping wire 3) Why you need to manage visual? For Terminal without crimped part,other parts are also important such as mating part,terminal lance,Stabilizer.Crimp Height management,pulling force management only check quality of crimped part.In addition,if Crimp Height and pulling force are suitable with allowance tolerance,but core wires and sheath aren’t crimped good state.They can’t guarantee good quality.Therefore,we must to manage visual.Three items below are important databases to manage visual 1.Comfirm mating part Mating part is play important role to combine this terminal with other terminal.Terminal is imported and guarantee by producer,but Crimped terminal is guaranteed by ourselves.If mating part is damaged,deformed,so erminal won’t combine together,and it’ll occur serious wrong case such as incorrect crimp height 2.Unsuitable crimping part at Wire barrel and Insulation barrel Core wire and sheath also have serious wrong case.If crimping state is broken a thread of core wire.Normally Crimp Height also became Crimp Height with height value.If sheath state is pulled inside wire barrel,so Crimp Height is achieve low value Any cases also have unsuitable Crimp Height 3.Deformed terminal If terminal is deformed up,down or twist.Unsuitable case can’t combine,or serious case is pushed away clamp.For OSƯ terminal is pushed away clamp,incorrect at mating part.For MESU terminal is pushed away clamp.When OSƯ terminal is deformed,we should to carefully KNOWLEDGE ABOUT ELECTRIC WIRE Crimp Height management: Confirming set value of Crimp Height (Knowledge of crimp Height card) Contents mention in the front side of crimp Height card KIẾN THỨC VỀ DÂY ĐIỆN Sự quản lý Crimp Height : Xác nhận giá trị đặt Crimp Height (Kiến thức thẻ crimp Height ) Nội dung đề cập phía bên thẻ crimp Height KNOWLEDGE ABOUT ELECTRIC WIRE A B Terminal name Applicator model Only write terminal name (call name of Furukawa AP),terminal in general is displayed on the back paper Is writing applicator name.Although it’s crimping similar terminal and electric wire.Crimp Height set number will different base on the each kind of applicator.So we must to confirm.In addition,depending on the each kind of applicator will have different colors for sheet [ general assembling terminal] [joint terminal] Only display tyoes and sizes of electric wires.It’ll display sizes if it’s Joint,except it is using specific wires For shield will show below: C Types-sizes Middle value of Crimp Height Make database to set up when start to operate.When start to operate must achieve middle value (middle value ± 0.02mm) (however only apply for tolerance which is displaying on card 0.025 or 0.05) E C/H ‘s Permissive range To check unequal lever while operating.Don’t pass this permissive range F Insulation Height Height of part hold on sheath must to set near medium value G Special note item Write for state of specific Insulation,rubber plug name,state to arrange wire,pulling force if it different with standard H Issue date D Write the issue date of Crimp Height card ... AV Low voltage wires for Automobile Used for normal circuit number At present is AV instead of AVS,AVSS AVS Low voltage and thin insulation AV type wires for Automobile Used for normal circuit... voltage Earth-bond wires for Automobile (thick insulation) Used for earth bond circuit number Earth battery wires EB Low voltage Earth-bond wires for Automobile Used for earth bond circuit number... insulation AV type wires for Automobile Used for normal circuit number ,core wire is pressed round shape and insulation part is thinner than AVSS AVO.OF Low voltage wires for Automobile.(flexible)