How do you identify the wrong orientation in complex wiring harness?

M

mechie

#1
Can anyone help me how to detect wrong orientation in a complex harness.. I would appreciate if any one can help..:agree:
 
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Marc

Hunkered Down for the Duration
Staff member
Admin
#2
What do you mean by wrong orientation? The wrong wires in a portion of the cable? If you can give me a bit more information about what you want to check I may be able to help.
 
M

mechie

#3
In a harness manufacturing company when complex harnesses are made there would be more than 50 connectors involved where wires of back & white are inserted some times balck instead of white is inserted in a connector.. Not only complex even in simple harness sometimes we tend to make this sort of mistake. How to get rid of this?
 
M

mechie

#4
Freinds my another question is " Is anyone aware of terminal microsection?" could anyone help me on this subject...
 
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Marc

Hunkered Down for the Duration
Staff member
Admin
#5
So the real question is how to prevent assembly mistakes?
 
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harry

Super Moderator
#6
So the real question is how to prevent assembly mistakes?
Mistake (error) proofing?


Microsections
A microsection allows the connector and wire combination to be assessed. It also allows the tool setting to be confirmed for a wire/termination combination which may be outside the crimp terminals specification. It can easily show up under or over crimping as well as cracking of the crimp barrel, lifting of the plating or uneven crimping.

A microsection can be produced in less than an hour if all the materials are available in the company. It can be useful technique if problems are being seen during other tests, like pull off or voltage drop measurement. Basically the crimp is mounted in a mould and epoxy resin is used to encapsulate the terminal prior to grinding the sample to the point of interest. This is normally at the point of compression. Ideally the section is ground to the centre of the compressed area and then examined. Which provides the possibility of grinding the section further if there are any areas of concern during initial preparation of the sample.

The section should show complete compression with the wire taking up and filling the cavity in the crimp barrel. The tool compression should be even on each side of the crimp and there should be no damage to the plating on the crimp terminal or any evidence of cracking of the barrel.
 

bobdoering

Stop X-bar/R Madness!!
Trusted Information Resource
#8
Yes! any solution or piece of idea which you could help me...
Most people that do harnesses use a board with clips to lay out all of the correct colors, lengths, locations, etc., prior to binding. Seems to be a common approach. Not sure if it error proofs. TO do that you might pass a small current through the holding clips, and if the correct ends are in the correct locations a green light would allow to proceed.
 

bobdoering

Stop X-bar/R Madness!!
Trusted Information Resource
#9
Friends my another question is " Is anyone aware of terminal microsection?" could any1 help me on this subject...
Yes, we do terminal microsectioning, also. Any specific question?
 
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M

mechie

#10
Yes, the current practice is the continuity test as the one you mentioned but, it is not a fool proof method.. this is not helping us to get rid of this...
 
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