1. Keywords:

Wiring Harness Processing Equipment

Wiring Harness Electrical Test Instrument

Wiring Harness Assembly Equipment

Battery Pack Wiring Harness Processing

High-Voltage/Low-Voltage Wiring Harness Assembly

Signal Wire Routing Station

Wiring Harness Terminal Crimping Machine

Wiring Harness Electrical Performance Test Instrument

Cable Processing Equipment

2. Introduction:

The Wiring Harness Assembly Station is used to process, install, and test various types of wiring harnesses (including signal wires, power cables, high-voltage cables, etc.) inside and outside the battery pack, ensuring the correctness and reliability of the electrical connections. The main equipment includes Wiring Harness Processing Equipment and Wiring Harness Electrical Test Instrument.

Wiring Harness Processing Equipment includes wire cutting machines, wire stripping machines, terminal crimping machines, wiring harness winding machines, wiring harness shaping molds, etc., which are used for wire cutting, stripping, terminal crimping, insulation sleeve installation, wiring harness shaping, and other processes.

The Wiring Harness Electrical Test Instrument is used to perform electrical performance tests on the completed wiring harnesses, including continuity tests, insulation tests, dielectric strength tests, etc., to ensure that the electrical performance of the wiring harnesses meets the specification requirements.

The Wiring Harness Assembly Station plays a key role in the production of lithium-ion battery packs, ensuring the correct and safe electrical connections within the battery pack, and providing a guarantee for the performance and safety of the battery pack.

3. Process Flow:

Cable Preparation

Cable Processing

Terminal Crimping

Insulation Sleeve Installation (optional)

Wiring Harness Shaping

Identification and Labeling

Electrical Performance Testing

Wiring Harness Installation

Final Inspection

4. Technical Specifications:

1）Wiring Harness Processing Equipment:

• Wire Cutting Length Range: 10-10,000mm

• Cutting Accuracy: ±0.5%

• Stripping Length: 0.1-50mm at the head end, 0.1-30mm at the tail end

• Applicable Wire Gauge: AWG30-AWG8 (0.05-8mm²)

• Crimping Force: 0.5-20kN

• Control System: PLC or Industrial PC

• Operation Interface: Touchscreen

2）Wiring Harness Electrical Test Instrument:

• Test Items: Continuity, Short Circuit, Insulation Resistance, Dielectric Strength

• Continuity Resistance Measurement: 0.1Ω-1MΩ, ±0.5%±0.1Ω

• Insulation Resistance Test: 1MΩ-1GΩ, ±2%

• Dielectric Strength Test: 50V-5kV, 0.1mA-100mA

• Test Points: 64-1024 points

• Data Storage and Communication: ≥1GB, USB/Ethernet/RS232

5. Technical Features:

1）Wiring Harness Processing Equipment:

• High-Precision Processing

• Multi-Functional Integration

• Strong Flexibility

• High Degree of Automation

• Safety and Reliability

• User-Friendly Interface

2）Wiring Harness Electrical Test Instrument:

• Comprehensive Test Capabilities

• High Accuracy and High Speed

• Intelligent Testing

• Programmable Testing

• Data Management

• Safety Protection

6. Application:

• Lithium-ion Battery Pack Production

• Automotive Manufacturing

• Electronics and Electrical Appliance Manufacturing

• Aerospace and Rail Transit

• Communication Equipment Manufacturing

• Other Industries Requiring Wiring Harness Processing