Common problems with custom electronic wiring harness assemblies

1. Improper initial testing of electronic wiring harnesses: When assembling custom electronic wiring harnesses for the first time, it is necessary to test several times to ensure that everything is connected and working effectively, because incorrect testing can lead to some dangerous failures.

Electronic wires should be 100% tested, especially where electrical connections are involved, where wires may initially be wired, welded or terminated improperly, leading to problems later on.

These repetitive failures can be easily resolved if the custom electronics line manufacturer conducts aggressive and thorough initial testing.

But not all tests will find malformations, for example intermittent failures are more difficult to detect because they don't happen often or regularly, and some indication needs to be looked for to determine whether the failure is caused by a repetitive, simple fix or a more difficult intermittent problem.

2.The tensile strength of the electronic wiring harness is improper: wires and cables should be able to withstand a reasonable force, in order to determine the tensile quality, the electronic wiring harness manufacturer should conduct a tensile test, which measures the strength of the internal structure of the wiring harness.

If the assembly is constantly losing connections or forcibly disconnecting, consider the tensile strength of the assembly.

3. The pressure imbalance of the electronic wiring harness: the crimping pressure refers to the correct setting of the mold in the custom electronic wiring harness assembly, if the technician fails to weld the structure or set the chip correctly, it may lead to internal wear and damage, and the pressure test should be able to clarify the problem factors.

4. Electronic wiring harness fretting problem: when the metal of the electronic wiring harness contact each other, they will form oxidation on the surface, if the application uses a lot of voltage, you can solve this problem, otherwise tin and lead are especially problematic.

While rewiring the wires can sometimes help, this is usually a temporary fix, and full plating can prevent some of these problems in the initial stages.

5. The contacts of the electronic wiring harness are improperly welded: when the electronic wiring harness is connected to other sources, they should be in their original state and properly welded and crimped.

When custom electronic wiring harness assemblies are not welded correctly, deposits can be left behind that can eventually interfere with the connection.