05. Cable & Wire Harness Assembly
Harness DFM, build, and test rules for production-ready interconnects.
Part 1. Design & Material Foundation (DFM)
Connecting point A to B is simple. Making it survive the real world is engineering. This chapter ...
1.1 Quality Baseline: IPC/WHMA-A-620 Classes
The IPC/WHMA-A-620 standard is the mandatory quality benchmark for the cable and wire harness ind...
1.2 Conductor Materials: The Electrical Core
The conductor is the functional heart of any wire harness. Its selection dictates not only the el...
1.3 Insulation & Cable Structures: Environmental Armor
If the conductor is the heart of the harness, the insulation and cable structure are its skin and...
1.4 Connector Families: The Mechanical Interface
The connector is the only part of the harness designed to be disconnected, making it the weakest ...
Part 2. Process Preparation (Cut, Strip, Prep)
Great harnesses aren't just designed; they are manufactured through disciplined repetition. This ...
2.1 Wire Preparation: Single Conductor Processing
Wire preparation is the high-speed automated foundation of the entire harness manufacturing proce...
2.2 Complex Cable Preparation
Processing complex cables requires a fundamental shift in mindset from simple connectivity to geo...
2.3 Tooling and Machine Capability
High-speed wire processing machines are the heartbeat of the harness shop, often producing thousa...
Part 3. Termination: The Critical Interface
This is where the connection actually happens—and where most failures begin. This chapter focuses...
3.1 Crimping Fundamentals
Crimping is the most critical process in wire harness assembly. It is not merely folding metal ar...
3.2 Crimp Quality Assurance
A finished crimp hides its internal quality. To the naked eye, a loose crimp and a perfect gas-ti...
3.3 Soldered and Ultrasonic Terminations
While crimping is the standard for high-volume termination, soldering and ultrasonic welding are ...
Part 4. Final Assembly and Validation
We have prepared the wire and terminated the ends. Now, we turn a collection of parts into a veri...
4.1 Form Board and Routing Design
The Form Board (or Jig Board) is the physical template that transforms a 2D engineering drawing i...
4.2 Identification and Labeling
Labeling is the "User Interface" of a wire harness. For the installer, it ensures correct connect...
4.3 Final Electrical Validation (CIR/HIPOT)
Visual inspection confirms workmanship, but only electrical validation confirms function. A harne...
4.4 Final Inspection and Traceability
Final inspection is the last line of defense before the product leaves the controlled factory env...