Wire harness welding is often used in automobile manufacturing. If you want to know the principles and benefits of wire harness welding, you can go to Branson. Branson not only has relevant introductions about wire harness welding, but also sells wire harness welding machines. Wire harness welding is a welding technology that solves the problem of automobile welding. Let me briefly introduce wire harness welding. You can get a preliminary understanding of wire harness welding through the following content. You can search online for more knowledge about wire harness welding.
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Traditional wire harness welding
The traditional wire harness welding processes mainly include: fusion welding, brazing, and pressure welding.
1) Fusion welding is a method of heating the workpiece interface to a molten state during welding and completing welding without pressure. During fusion welding, the heat source quickly heats and melts the interface of the two workpieces to be welded to form a molten pool. The molten pool moves forward with the heat source, and after cooling, a continuous weld is formed to connect the two workpieces into one. After fusion welding, the wire harness interface is combined in a fusion bud shape to form a weld nodule, which has high resistance and greatly reduces the service life of the wire harness. In addition, during fusion welding, if the atmosphere is in direct contact with the high-temperature molten pool, the oxygen in the atmosphere will oxidize the metal and various alloy elements. Nitrogen, water vapor, etc. in the atmosphere enter the molten pool, and defects such as pores, slag inclusions, and cracks will be formed in the weld during the subsequent cooling process, which will deteriorate the quality and performance of the weld.
2) Brazing is a method of using a metal material with a lower melting point than the workpiece as a brazing material, heating the workpiece and the brazing material to a temperature higher than the melting point of the brazing material and lower than the melting point of the workpiece, using the liquid brazing material to wet the workpiece, fill the interface gap and achieve mutual diffusion between atoms with the workpiece, thereby achieving welding.
The joint formed by welding to connect the two connected bodies is called a weld. Both sides of the weld will be affected by welding heat during welding, and the organization and performance will change. This area is called the heat-affected zone. During welding, due to differences in workpiece materials, welding materials, welding current, etc., overheating, embrittlement, hardening or softening may occur in the weld and heat-affected zone after welding, which will also reduce the performance of the weldment and worsen the weldability. This requires adjusting the welding conditions. Preheating the weldment interface before welding, heat preservation during welding, and heat treatment after welding can improve the welding quality of the weldment.
3) Pressure welding is to achieve atomic bonding between two workpieces in the solid state under pressure, also known as solid-state welding. The commonly used pressure welding process is resistance butt welding. When the current passes through the connecting ends of the two workpieces, the temperature rises due to the large resistance. When heated to a plastic state, they are connected into one under the action of axial pressure.
The common feature of various pressure welding methods is that pressure is applied during the welding process without adding filler materials. Most pressure welding methods such as diffusion welding, high-frequency welding, and cold pressure welding do not have a melting process, so there is no problem of beneficial alloy element burning and harmful elements invading the weld like fusion welding, which simplifies the welding process and improves welding safety and sanitation conditions. At the same time, because the heating temperature is lower than that of fusion welding and the heating time is shorter, the heat-affected zone is small. Many materials that are difficult to weld with fusion welding can often be welded into joints with the same strength as the parent material by pressure welding.
Advantages of wire harness welding machine
(1) The welding material does not melt and does not break the metal properties. (2) After welding, the conductivity is good, and the resistivity is extremely low or close to zero. (3) The requirements for the surface of the welded metal are low, and both oxidation and electroplating can be welded. (4) The welding time is short, and no flux, gas, or solder is required. (5) There is no spark in the welding, which is environmentally friendly and safe.
Automobile wiring harness welding process
1. Wire stripping:
When stripping wires with wire strippers, pay attention to not damaging the wires of single-strand wires, and do not break the wires of multi-strand wires and shielded wires, otherwise it will affect the quality of the joints. When stripping multi-strand wires, pay attention to twisting the wire core into a spiral shape. The stripping length is operated according to the requirements of the process data.
2. Pre-soldering: Pre-soldering is a key step in wire welding. When tinning the wire, it should be rotated while tinning. The direction of rotation is consistent with the direction of screwing. When tinning multi-strand wires, pay attention to the “candle wick effect”, that is, the solder enters the insulation layer, causing the soft wire to harden, which is easy to cause joint failure. 3. Heating: First use the preheated iron head to heat the component leads and pads. 4. Wire feeding: Hold the tin wire on the left and right and send it to the heated soldering area. 5. Leave: After the solder wire melts and slowly flows to two-thirds of the entire pad area, quickly evacuate the solder wire and iron head. 6. Solidification: The iron head is reversed. After evacuation, do not shake the components and circuit boards. Let the solder joints solidify naturally. For components that are easily burned, blow air on the solder joints to accelerate solidification.
7. Inspection:
Inspect the welding quality, requiring the solder joints to have a moderate amount of tin, bright solder joints, and firm welding.
Wire harness welding is mainly used for welding wire harnesses. At present, it is more commonly used in the electronics industry because the electronics industry uses more wire harnesses. You can learn some relevant knowledge about wire harness welding, or learn some methods of wire harness welding, which is very helpful for improving your own skills. Wire harness welding is relatively difficult, so you must study it seriously.
Post time: Nov-18-2024
