Provjera kvaliteta spojnih kablova za automobile

Automobilski kabelski svežanj važan je dio modernih automobila i glavni dio automobilskih kola. Usmjeravanje struje na različite električne komponente u automobilu igra značajnu ulogu u ostvarivanju namjera ljudi u automobilu. Korištenje ljudskog tijela kao reprezentacije, motor je ekvivalentan ljudskom srcu, a kabelski svežanj je poput krvnih sudova ili nervnog sistema ljudskog tijela.
Među raznim problemima s kvarom automobila, štetni efekti uzrokovani kabelskim svežnjama čine značajan udio. Ako žice, guma, creva, itd. u ožičenju su oštećeni, uzrokuje kratki spoj ili prekid strujnog kruga u žici, oštetit će funkciju prijenosa. To ne samo da će uzrokovati prestanak kretanja različite opreme, ali u zavisnosti od stepena, takođe može uzrokovati dim, vatre, nemogućnost hodanja, okreni se, kočnice i drugi veliki problemi.
Budući da kabelski svežanj zauzima tako važnu poziciju u cijelom automobilu, kao menadžer kvaliteta u fabrici za proizvodnju automobila, potrebno je fokusirati se na kontrolu i striktno upravljanje pitanjima kvaliteta kabelskog svežnja. Kako bi se kupci sa povjerenjem i udobnošću vozili u svojim automobilima, kvalitet kabelskog svežnja mora se provjeriti kroz sistematski i profesionalni pristup. Ova metoda je certifikat ožičenja, naziva se i W.P.T inspekcija. Ova tačka gledišta je takođe i tačka gledišta verifikacije kabelskog svežnja.
Ovaj članak govori o inspekcijskim perspektivama rada inspekcije kabelskog svežnja koje je potrebno primijeniti kao menadžeri kvalitete tokom procesa inspekcije kabelskog svežnja..

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1 – Pregled certifikata ožičenja
Inspekcija kabelskog svežnja naziva se W.P.T inspekcija. W.P.T je akronim za WIRE, PIPE, i TUBE. Općenito se odnosi na dijelove kao što su kabelski svežnja, kablovi, crijeva i gumene cijevi. Provjera da li ima oštećenja je W.ET pregled.
Tokom faza razvoja i probne proizvodnje novih modela Dongfeng Honda, tvornički kvalitetno osoblje mora završiti inspekcije kabelskog svežnja u određenim fazama. A pregled kabelskog svežnja u svakoj fazi je drugačiji (vidi sliku 1).

Figura 1 Inspekcija kabelskog svežnja tijekom faza razvoja i probne proizvodnje novih modela Dongfeng Honda
Iako su sadržaj i oblik inspekcije kabelskog svežnja u svakoj fazi različiti, gledište inspekcije na osnovu svake inspekcije kabelskog svežnja je isto. Sa ovim perspektivama, problemi se mogu efikasno otkriti i rešiti, čime se poboljšava kvalitet i sprečava da neispravni proizvodi pređu u sledeći proces.

2 – Perspektiva verifikacije kabelskog svežnja
Uobičajeni problemi sa ožičenjem uključuju: smetnje, ugristi, nedovoljan CL, poteškoće u instalaciji, neuspjeh instalacije, pogrešno sastavljanje, povlačenjem, istezanje, itd. Kao odgovor na ove probleme, Osoblje za inspekciju kabelskog svežnja koristit će odgovarajuća gledišta za pronalaženje i rješavanje problema.
Radi lakšeg objašnjenja, problemi koji se javljaju u različitim inspekcijama kabelskog svežnja klasificirani su u nastavku kako bi se raspravljalo o perspektivama kojih se treba pridržavati tokom procesa inspekcije kabelskog svežnja.

2.1 Interferencija
Nakon završene montaže kompletnog vozila, ako oštri rubovi kabelskog svežnja dođu u kontakt s perifernim dijelovima kabelskog svežnja (lim, trim paneli, funkcionalni dijelovi, itd.) i postoji interakcija sila, to znači da kabelski svežanj i predmet međusobno ometaju. Problemi s smetnjama su najlakši i najčešći problemi u verifikaciji kabelskog svežnja (vidi sliku 2).
Figura 2 Uobičajene smetnje u ožičenju
Uzimajući u obzir mogućnost smetnji između kabelskog svežnja i plave kontrolne kutije, možete izračunati CLIP1, CLIP2 tačke ~ dužina Utačke b. Ako je zbroj manji od dužine pojasa na MAX toleranciji, doći će do smetnji. Ako je dužina veća od MAX tolerancije kabelskog svežnja, neće doći do smetnji.
Kroz kalkulaciju, udaljenost od CLIP1 do tačke b: l01 mm
Udaljenost od CLIP2 do tačke b: 200.5 mm
Kada je dužina stabla do 305 m, 305>101+200.5, Doći će do smetnji između kabelskog svežnja i kontrolne kutije.
Po proširenju, ako su tri vrijednosti podataka A, B, i D se mijenjaju (C=A+B), kako će se određivanje smetnji u kabelskom svežnja promijeniti? Determining whether the wire harness interferes with the control box can be calculated by calculating the distance between the two closest fixed points of the possible interference part of the wire harness and the possible interference points of the component. In the early stage, when there is only a wiring harness but no completed car, you can use this to find possible areas of interference as key locations.

2.2 Cut
Wire harness cutting is the most obvious manifestation of interference between the wire harness and surrounding components, and it more directly reflects the consequences of wire harness interference. Cutting the wire harness will cause the broken copper wires of the wires to be exposed or the wires to be cut, causing a short circuit or open circuit. Its external manifestation is that the relevant functions do not operate, and in more serious cases, the car may burn.
In the entire vehicle, due to the spatial structure, the routing design of the wiring harness inevitably passes through some compact areas. A perfect hands-off layout is impossible to achieve in an actual finished car. U ovom trenutku, it is necessary to consider whether there may be a hidden danger of cutting the wire harness in the area where the wire harness must be in contact with surrounding components. So in wire harness inspection, how to determine the risk of cutting at the interference part, there are the following factors to consider.

2.2.1 Protection form of wire harness
The wiring harness has the following forms of protective exterior: TwiStTube, Corr Tube, PVC Tube, PVC Tape, Urethane Foam, CushionTape.
Each type of exterior has different models, but the basic physical and chemical properties of the same exterior among different models are roughly the same. Appropriate protective outer covering can be selected for the wiring harness according to its characteristics.
As far as the hidden danger of wire harness cutting is concerned, mainly based on the wear-resistant strength of the exterior, the above exteriors can be simply sorted. From strong to weak: Twist Tube>CorrTube>CUSHION Tape>PVC Tube>URETHANE FOAM>PVC Tape.

2.2.2 Drawing properties of wire harness
Refer to the 2D drawing to determine the line length, exterior decoration and model between the two fixed points of the interference part. Considering the tolerance of the wire length, what is the degree of wire harness interference in the extreme MAx or MIN state? What kind of wire harness exterior is used, what is the model, and whether it has the protective effect in the current environment: Sometimes corrugated pipe (Corr Tube) is not wrapped with PVC tape around the outside. If the type of corrugated pipe used is inappropriate, the wires may jump out of the opening of the corrugated pipe. U ovom slučaju, you need to pay attention to the possibility of interference from the surrounding area.

2.2.3 Material of contact parts
If there is relative movement and friction between the contact parts, it may cause the wire harness to be cut. By default, sheet metal sharp edges cannot interfere with wire harnesses that are not wrapped with corrugated tubes (CorrTube) or Twist Tubes (Twist Tube). There are welding spots in the sheet metal welding parts. If there are long burrs at the solder joints and the wire harness is close to the burrs, the burrs may penetrate deep into the wire harness and pierce the wires, causing the wire harness to be cut.

2.2.4 Contact part shape
The wire harness protected by the corrugated tube comes into contact with the sharp edge of the sheet metal. Although it is protected by the corrugated tube, if the relative positions of the corrugated tube and the sharp edge are perpendicular to each other, the wire harness may be cut.

2.3 Occlusion
The occurrence of the bite phenomenon is basically due to the fact that the wiring harness direction (may be the design direction, or may be the direction fluctuation caused by tolerance fluctuation) is exactly located at the assembly position of the surrounding components. Kao rezultat, the wiring harness is squeezed between the two mating parts.
During the wire harness inspection process, it is sometimes found that the wire harness is stuck between parts. Sometimes it may be because the wire harness naturally sag due to gravity, and sometimes it may be due to tolerance fluctuations where the wire harness is too long or too short, causing bites.
The wiring harness mainly consists of wires and their protective outer coverings. Wiring harness inspection is to ensure that the wires in the wiring harness are not damaged by external forces and affect their functions. Stoga, slight deformation of the protective exterior can be accepted by quality personnel as long as it does not cause damage to the wires. In other words, as long as the degree of bite does not affect the wires in the wiring harness, it can be considered that there is no problem with the wiring harness here.

3-Zaključak
As an important part of electrical installation work, wire harness inspection requires quality management personnel to continuously improve their professional knowledge and accumulate experience based on the inspection results of various models. I hope that the above views on wire harness inspection can serve as inspiration and form a complete and mature view on wire harness inspection.
Ubuduće, if the entire vehicle wiring harness can be evaluated from the perspective of the designer, quality manager, and assembler combined with the designer’s design perspective, then the wiring harness verification work can be advanced more comprehensively. It also ensures that customers get the most comfortable user experience.