The quality of new energy storage wiring harness is directly related to the safety and performance of the energy storage system. From the entry of raw materials into the factory to the delivery of finished products, every link needs to be strictly controlled. Quality control runs through the entire production process. Only through layers of checks can we ensure that the new energy storage wiring harness meets high standards.
Raw material inspection is the primary line of defense for quality control. The main materials of new energy storage wiring harness include wires, insulating materials, connectors, etc., each of which needs to be strictly screened. The material purity and cross-sectional area of the wire directly affect the conductive performance. Poor-quality wires may cause excessive resistance and severe heat generation, so it is necessary to conduct detailed inspections of its material composition and physical properties. Insulating materials are related to safety and must have good flame retardant and aging resistance. By checking its tear strength, temperature resistance and other indicators, short circuits or leakage accidents caused by insulation failure can be prevented. The quality of the connector is also critical. Its parameters such as plug-in force and contact resistance determine the stability of the connection. Any slight defect may cause poor contact and affect the normal operation of the energy storage system.
The processing and manufacturing process of new energy storage wiring harness is the core link of quality formation. In the wire cutting process, the length of the wire and the stripping length must be accurate. Too long or too short will affect the subsequent assembly and use performance. The crimping process is the top priority. The crimping quality of the terminal and the wire is directly related to the reliability of the electrical connection. If the crimping force is too light, the terminal and the wire are not tightly combined, which is easy to cause increased contact resistance, heating or even wire breakage; if the crimping force is too heavy, it may damage the wire and reduce the mechanical strength. Therefore, it is necessary to strictly control the parameters of the crimping equipment and ensure that each crimping point is firm and reliable through means such as tensile testing.
Quality control during the assembly process should not be ignored either. The wiring and bundling methods of the new energy storage wiring harness will affect its mechanical properties and anti-interference ability. Unreasonable wiring may cause the new energy storage wiring harness to be entangled and squeezed with each other, and the insulation layer will be worn out during long-term use; irregular bundling will make the new energy storage wiring harness loose and increase the risk of friction during vibration. In addition, the assembly matching degree of the new energy storage wiring harness with the connector and equipment is also crucial. Any size deviation or inadequate installation may affect the electrical connection and mechanical stability. The assembly quality must be guaranteed by precise fixtures and strict operating specifications.
Online testing is a key means to find quality problems in time. Through electrical performance testing, the conductivity, insulation resistance, withstand voltage performance and other indicators of the new energy storage wiring harness can be tested to ensure that it meets electrical safety requirements. For high voltage and high current application scenarios in new energy storage systems, any slight electrical defects may cause serious consequences, so electrical testing must be comprehensive and strict. At the same time, with the help of appearance inspection, dimension measurement and other means, scratches and damage on the surface of the new energy storage wiring harness, as well as the installation dislocation of the connector, can also be found, and repairs or rework can be carried out in time to prevent unqualified products from flowing into the next process.
Finished product inspection is the last checkpoint of quality control. In addition to repeating the various items of online testing, it is also necessary to simulate the actual use environment and conduct reliability tests such as aging test, vibration test, high and low temperature test, etc. The aging test accelerates the performance decay of the new energy storage wiring harness by long-term power-on to test its long-term stability; the vibration test simulates the vibration environment when the vehicle is driving or the equipment is running to evaluate the vibration resistance of the new energy storage wiring harness; the high and low temperature test can examine the performance of the new energy storage wiring harness under extreme temperature conditions to ensure that it can work normally in various environments.
Quality control is also inseparable from the management of the production process and personnel training. Establish a sound production management system, clarify the operating specifications and quality standards of each process, and through regular quality statistical analysis, timely discover potential problems in the production process and improve them. At the same time, strengthen the skills training and quality awareness education of operators so that they can master the production process proficiently, strictly abide by the operating procedures, and reduce quality problems caused by human factors from the source. Only through the above multi-link and all-round quality control measures can the high-quality production of new energy storage wiring harness be guaranteed, laying a solid foundation for the safe and stable operation of the energy storage system.
