30-08-2014, 09:39 AM
I express my sincere thanks to ‘YAZAKI (INDIA) LIMITED’, for providing me the opportunity to get help and instructions about wiring harness. I would also like to acknowledge the efforts of Er. GANESH PATIL and Er. KAILASH SINDE providing me the necessary documents and instructions essential for me to complete this work . I would also like to thanks SATNAM SINGH MATHARU and Er. AKSHAY AGNIHOTRI for their efforts from CTIEMT shahpur Jalandhar’ much needed moral support and encouragement is provided on numerous occasions by my whole family and friends. And finally, I would like to thank the GOD for his kind blessing to complete this work successfully. Without blessing, it was impossible to complete this work.
THE TRAINING REPORT
OF
Six Months Industrial Training
IN
YAZAKI (INDIA) LIMITED
SUBMITTED TO SUBMITED BY
Satnam Singh Matharu Raushan Kr Mishra&santosh kumar
Electrical Department 100220520902,100220520904 EE-8TH
CTIEMT Shahpur, Jalandhar B. TECH. (CTIEMT)
ACKNOWLEDGEMENT
I express my sincere thanks to ‘YAZAKI (INDIA) LIMITED’, for providing me the opportunity to get help and instructions about wiring harness. I would also like to acknowledge the efforts of Er. GANESH PATIL and Er. KAILASH SINDE providing me the necessary documents and instructions essential for me to complete this work . I would also like to thanks SATNAM SINGH MATHARU and Er. AKSHAY AGNIHOTRI for their efforts from CTIEMT shahpur Jalandhar’ much needed moral support and encouragement is provided on numerous occasions by my whole family and friends.
And finally, I would like to thank the GOD for his kind blessing to complete this work successfully. Without blessing, it was impossible to complete this work.
DECLARATION
I am the student of B-Tech EE-8th semester; hereby declare that this report is the record of authentic work carried by me during the industrial training from 20th December 2013 to 20 may 2014 in ‘YAZAKI (INDIA) LTD’ at Wagholi Pune .
PREFACE
This mid semester report’s file uses plain and lucid language to explain about wiring harness which is used in cars and the devices used in harness manufacturing. In this file main part is about Head light harness, Indicator harness, Lighting harness, Navigation harness, Bluetooth harness and many more. Any suggestion for the improvement of the file will be acknowledged and well appreciated.
CONTENT
Sr. No.
TOPIC
REMARKS
1.
BRIEF PROFILE OF THE COMPANY/INDUSTRY
· YAZAKI (INDIA) LIMITED.
2.
OVERVIEW OF THE PROJECT UNDERTAKEN
· WIRING HARNESS
3.
WORK DONE
· TESTING WIRING HARNESS CONDUCTIVITY
4.
PROCESS AND DIFFERENT EQUIPMENTS FOR MANUFACTURING.
5.
TESTING OF HARNESSES.
6.
LAYOUT OF HARNESSES AND DESIGN PRACTICES.
7.
WIRING HARNESSES FOR NEXT GENERATIONS AUTOMOBILES
8.
CONCLUSIONS.
COMPANY PROFILE
About company
Yazaki Corporation
Yazaki Corporation is an independent automotive component maker founded in 1941 by YASUHIKO YAZAKI. As well as automotive wire harnesses, develop and manufacture meters, electronic components and a host of other products for automotive use.
Since first overseas production site was established in Thailand in 1962, global development and manufacturing network has continued to grow, along with relationship of mutual trust with car manufacturers around the world.
With "A Corporation in Step with the World" and "A Corporation Needed by Society" as corporate policy, committed to being environment-friendly in every aspect of business. Developed and produced a long line of eco-friendly and energy saving products, starting with the world's first solar thermal powered air conditioning system in 1974, to the world's first wood biomass energy air conditioning system in 2008.
Yazaki Corporation is dedicated to caring for the environment, making a contribution to society and inspiring trust in all stakeholders.
The company was originally incorporated by Siemens in 1998 to supply wiring harness to Ford India Private Limited (FIPL).
In 2002, the company was converted into a 50% JV between Siemens AG and the Yazaki Corporation, Japan and the company was re-named Siemens Yazaki Wiring Technologies. Subsequently in 2004, Yazaki Wiring Technologies, Germany a wholly owned subsidiary of Yazaki Corporation Japan acquired the complete ownership of the company and renamed it Yazaki Wiring Technologies India Private Limited (YWTI).
YWTI is the sole supplier of wiring harness FIPL for passenger cars (B segment vehicles) with nearly 98% of its revenue derived from sales to FIPL. Apart from FIPL, the company also supplies harnesses for “Mitsubishi Lancer” to Hindustan Motors Limited.
The Company has started supplying to Daimler India Commercial Vehicles Private Limited in the current fiscal. Yazaki Corporation, headquartered in Minato-ku, Tokyo (Japan), is a 100% privately owned corporation with a diverse range of products in the global automotive and environmental systems sectors.
Yazaki is one of the largest producers of automotive wiring harnesses in the world.
Over the years, The Yazaki Group has achieved a significant global presence with 169 companies and 410 business sites in 39 countries. It has production facilities in the USA, Mexico, South America, Africa, Australia, Southeast Asia, India and China as well as throughout Europe.
GLOBAL NETWORK
PRODUCTS
Cars
Homes
Annual Report
Consolidated sales
Breakdown of net sales by region
Wiring harness.
Wire harnesses are compactly bundled wires and data circuits that function as the central nervous system of a vehicle. To ensure safety and basic functions (going, turning and stopping), as well as provide comfort and convenience, automobiles are equipped with various electronics which operate using control signals running on electrical power supplied from the battery. The wire harness is the conduit for the transmission of these signals and electrical power.
TYPES OF WIRING HARNESS
1 Head light harness.
2 Indicator light harness.
3 Lighting harness.
4 Instrument cluster harness.
5 Rear camera harness.
6 Trailer harness.
7 Bluetooth harness.
8 Navigation harness.
9 LPG harness.
FUNCTION
The main function of a harness is to transmit power to the different components and modules in the automotive. The range of complexity for a wiring harness depends by the quantity of wires and components required for complete its assembly.
Basics Terms:
Accessories: Mechanical devices, such as cable clamps, added to connector bodies.
Adapter :An intermediate device to provide for attaching special accessories or to provide specialmounting means.
Barrel (Contact Wire Barrel) :The section of contact that accommodates the strippedconductor.
Birdcaging: The radial expansion of individual strands in a stranded conductor (bowing outward)that can occur in the exposed portion of the conductor between the insulation strip and
termination point.
Braid: A fibrous or metallic group of filaments interwoven to form a protective covering over oneor more wires.
Breakout: The separation of a conductor or group of conductors from the main body of wires ina harness.
Bubble Pack: A laminated plastic sheet that is formed with patterned air entrapment ("bubbles"). The bubbles provide excellent cushioning for anything enclosed between layers of the material.
Cable: A shielded single conductor or a combination of conductors insulated from one another
(multiple conductor).
Cable, Coaxial: A cable in which an insulated conductor is centered inside another. The outer
conductor is usually a metal braid or metal sheath. Braided cables usually have an outer insulatingjacket over the braid. Coaxial cables are used primarily for transmission of RF signals.
Cable, Shielded: One or more insulated conductors covered with a metallic outer covering,
usually a metal braid.
Cable Clamp: A mechanical clamp attached to the wire entrance of a connector to support the
cable or wire bundle, provide stress relief, and absorb vibration and shock.
Certification: The act of verifying and documenting that personnel have completed required
training, have demonstrated specified proficiency, and have met other specified requirements.
Cold Flow: Movement of insulation (e.g., Teflon) caused by pressure.
Conductor:A lead or wire, solid, stranded, or printed wiring path serving as an electrical
connection.
Connector, Body: The main portion of a connector to which contacts and other accessories are
attached with it.
Connector, Grommet: An elastomeric seal used on the cable side of a connector body to seal theconnector against contamination and to provide stress relief.
Connector, Insert:The part of a connector that holds the contacts in position and electrically
insulates them from each other and the shell.
Contact:The conductive element in a connector or other terminal device that mates with a
corresponding element for the purpose of transferring electrical energy.
Contact, Crimp: A contact whose crimp barrel is a hollow cylinder that accepts the conductor.
After a conductor has been inserted, a tool is used to crimp the contact metal firmly onto the
conductor.
Contact, Insertable/Removable: A contact that can be mechanically joined to or removed from an insert. Usually, special tools are used to insert (lock) the contact into place or to remove it.
Contact, Pin: Male-type contact designed to slip inside a socket contact.
Contact Retention: The axial load in either direction that a contact can withstand without being
dislodged from its normal position within an insert or body.
Contact, Socket: A female-type contact designed to slip over a pin contact.
Contaminant: An impurity or foreign substance present in a material that affects one or more
properties of the material. A contaminant may be either ionic or nonionic. An ionic, or polar
compound, forms free ions when dissolved in water, making the water a more conductive path. A
nonionic substance does not form free ions, nor increase the water's conductivity. Ionic
contaminants are usually processing residue such as flux activators, finger prints, and etching or
plating salts.
Crimp: The physical compression (deformation) of a contact barrel around a conductor to make an electrical and mechanical connection to the conductor.
Crimping: A method of mechanically compressing or securing a terminal, splice, or contact to a conductor.
Drain Wire: A wire that runs linearly along a foil shield wire or cable and is used to make contactwith the shield. Grounding of foil shields is done with drain wires.
Electromagnetic Interference: The unwanted intrusion of electromagnetic radiation energy
whose frequency spectrum extends from subsonic frequency to X-rays.
Ferrule: A short metal tube used to make crimp connections to shielded or coaxial cables.
Fillet: A smooth concave buildup of material between two surfaces; e.g., a fillet of solder betweena conductor and a solder terminal.
Grommet: An insulator that covers sharp edges of holes through panels and partitions to protect wire insulation from cut-through damage.
Harness: One or more insulated wires or cables, with or without helical twist; with or without
common covering, jacket, or braid; with or without breakouts; assembled with two or more
electrical termination devices; and so arranged that as a unit it can be assembled and handled as
one assembly.
Insertion Tool :A device used to install contacts into a contact cavity in a connector insert.
Interfacial Seal: A sealing of mated connectors over the whole area of the interface to provide
sealing around each contact.
Jacket:The outermost layer of insulating material of a cable or harness.
Joint:A termination.
Mate: The joining of two connectors.
Molding: The sealing of a connector backshell area or a cable breakout with a compound or
material that excludes moisture and provides stress relief. The material is injected into molds that
control its configuration.
Offgassing: The release of a volatile part(s) from a substance when placed in a vacuum
environment that may affect crew members.
Outgassing: The release of a volatile part(s) from a substance when placed in a vacuum
environment.
Radio Frequency: The frequency spectrum from 15 kHz to 100 GHz. Cables are seldom used
above 18 GHz.
Radio Frequency Interference: Electromagnetic radiation in the radio frequency spectrum from 15 kHz to 100 GHz.
Sealing Plug: A plug that is inserted to fill an unoccupied contact aperture in a connector. Its
function is to seal an unoccupied aperture in the assembly, especially in environmental connectors.
Shielded Cable: Cable surrounded by a metallic covering intended to minimize the effects of
electrical crosstalk interference or signal radiation.
Shielding:The metal covering surrounding one or more conductors in a circuit to prevent
interference or signal radiation.
Solder: A nonferrous, fusible metallic alloy used to join metallic surfaces.
Solder Cup Terminal: A hollow, cylindrical terminal designed to accommodate one or more
conductors.
Soldering: The process of joining clean metallic surfaces through the use of solder without direct fusion of the base metals.
Solder Sleeve: A heat-shrinkable solder termination device with meltable sealing preforms at
ends.
Splice: The joining of two or more conductors to each other.
Spacecraft: Devices, manned or unmanned, which are designed to be placed into a suborbital
trajectory, an orbit about the earth, or into a trajectory to another celestial body.
Strain Relief: A connector device that prevents the disturbance of the contact and cable
terminations.
Stranded Conductor: A conductor composed of a group of smaller wires.
Stress Relief:The formed portion of a conductor that provides sufficient length to minimize
stress between terminations.
Strip: To remove insulation from a conductor.
Supplier: In-house NASA, NASA contractors, and subtier contractors.
Tab Terminal: A flat-surface terminal that is broad compared to the metal thickness. Wires are
often soldered along the flat surface.
Tang (Connector Backshell) :A backshell tang is a tapering metal projection (straight, 45°, or
90° to the axis of the connector) designed to accommodate cable-tie attachments. The cable-ties
grip and hold harness wires exiting from the connector, thus providing stress relief for the wires.
Tines: Tines are the members of a contact retention system that capture or "lock" removable
crimp contacts into the contact cavities.
Wicking: A flow of molten solder, flux, or cleaning solution by capillary action.
Wire: A single metallic conductor of solid, stranded, or tinsel construction, designed to carry
currents in an electrical circuit. It may be bare or insulated.
Wire Dress: The arrangement of wires and laced harnesses in an orderly manner.
PROCESS AND DIFFERENT EQUIPMENTS FOR MAKING HARNESS:
1. Cutting and crimping
2. Preparation of circuits and subassemblies
3. Assembly Process (manufacturing strategies)
4. Testing (Electrical Continuity and visual inspection)
Cutting and Crimp Termination
The first part of the wiring harness manufacturing process is the preparation of the
“circuits”. Circuit is a wire cut at the required length and with terminals in one or both
ends, in other words is the raw material converted useful component for the wiring
harness assembly.
The parameters that define a circuit are the color, insulationmaterial, gage, strands and terminals. Other characteristics often used are wire sealand shrinking tubes. About 100
circuits compound a typical medium size harness.
The document that encloses all characteristics for particular circuit is the Cut sheet.
The information required to develop the cutsheet comes from the wiring harness
blue print and translated in manufacturing terms.
The typical equipment that is required during this phase is an automatic cutting
machine. This machine is a high tech piece of equipment drive by the use of a
computer. The operator will introduce the circuit parameters in its memory and set
up the tooling and material required.
The different types of machine used in crimping, cutting and stripping are:
Kodera.
AC-90.
YMC.
Bonder.
CS-571
TV-11.
Shield wire machine
Twisting machine
and many more.
Different tools used:
Applicator
Micrometer
Multimeter
Pressure guage
Chuck guage
Twisting and many more.
The wire is pull from the wire-packaging barrel by the feeding system in anautomatic wire processing machine and cut the raw wire to the required length. Ashort length of insulation is remove from both ends of the circuit. A mechanical armwill hold the end of the circuit and lead it to the die applicator station, passing thougha sensor, which will verify that the circuit end has been strip correctly.
Once thecircuit end arrives to the die applicator station and it is in correct position, themachine will activate a 5-ton press to apply the terminal. The terminal is present in aroll loaded over a carrier strip and is pull from the die applicator. Finally, the circuit isdeliver to a container, which is release in batches. The cycle of this complete circuitprocessing takes only a few seconds and will be repeating as the quantity desire.
Almost all parameters in the cutter are easy to adjust according to the circuitcharacteristics with the exception of the terminal applicator. The terminal die is acustomized tool for each type of terminal, and is adjust for particular wire sizeinsulation and terminal combination.
The optimization of the cutter machine in largewill depends of the capacity for performing a quick tooling change in the machine.Some smed techniques are use in order to minimize the set-up time. For low volumeof circuits is necessary to create a buffer of circuits in order to optimize the machineset-up.
During this phase, crimping is the most critical operation because is going todeterminate the electrical continuity between the terminal and wire. There are twoparameters considered in direct relationship with conductivity. Those parametersmust be monitoring in order to assure the quality of the crimping. First the pull forcerequired to remove a crimped terminal from the wire and the second is the shape ofthe crimping area (high and width dimensions).
Each terminal type will require different high and width parameters and actuallydifferent gages of the same terminal type will also require different parameters.
Because the importance of having a good crimping condition the process requiresvery, close monitoring. Since the cutting rate is about 3,000 circuits per hour is verydifficult the implementation of SPC.
A very good aid for monitoring 100% of theproduction is a device called crimp force monitor (CFM). The CFM is an electronicdevice connected to the CPU of the cuter. The CFM will compare a curve of forcerequired by the system to apply good crimping Vs every single application thatfollows the same pattern.
When there is a terminal change a new curve, have to begenerating with the first ten samples. The material variation (terminal and wire),defective wire processing, wrong material and mechanical failures are the reasonsof deviation from the sample curve.
Once the cutting and crimping process are complete the some circuits will go directlyto the assembly line and others will go to the Preparation of circuits andsubassemblies area
.
The first part of the wiring harness manufacturing process is the preparation of the“circuits”. Circuit is a wire cut at the required length and with terminals in one or bothends, in other words is the raw material converted useful component for the wiringharness assembly. The parameters that define a circuit are the color, insulationmaterial, gage, strands and terminals.
Other characteristics often used are wire sealand shrinking tubes. About 100 circuits compound a typical medium size harness.
The document that encloses all characteristics for particular circuit is the Cut sheet.The information required to develop the cut sheet comes from the wiring harnessblue print and translated in manufacturing terms.
Samples of different circuits
The typical equipment that is required during this phase is an automatic cuttingmachine. This machine is a high tech piece of equipment drive by the use of acomputer. The operator will introduce the circuit parameters in its memory and setup the tooling and material required.
The wire is pull from the wire-packaging barrel by the feeding system in anautomatic wire processing machine and cut the raw wire to the required length. Ashort length of insulation is remove from both ends of the circuit.
A mechanical armwill hold the end of the circuit and lead it to the die applicator station, passing thougha sensor, which will verify that the circuit end has been strip correctly. Once thecircuit end arrives to the die applicator station and it is in correct position, themachine will activate a 5-ton press to apply the terminal.
The terminal is present in aroll loaded over a carrier strip and is pull from the die applicator. Finally, the circuit isdeliver to a container, which is release in batches. The cycle of this complete circuitprocessing takes only a few seconds and will be repeating as the quantity desire.
Almost all parameters in the cutter are easy to adjust according to the circuitcharacteristics with the exception of the terminal applicator.