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Wire Harness Assembly Methods

An introduction to the wire harness manufacturing process


This training Wire Harness Assembly Methods provides an introduction to the wire harness manufacturing process.
The training Wire Harness Assembly Methods begins by explaining the basic functions of the board, components and wire harness. It clearly demonstrates the entire fabrication process, including:

  • drawings and specification review;
  • wire preparation (cutting, stripping and tinning);
  • shaping the harness;
  • wire termination processes (soldering and crimping);
  • tying the harness;
  • inspection,
  • testing,
  • quality assurance standards;
  • shipping;
  • installation
  • and safety considerations.

Produced in cooperation with the Wire Harness Manufacturers Association.

Duration

Certification: 2 days including exam

Recertification: 1 day including exam

Challenge test: 0,5 day only exam


Course materials

Each participant will receive a summary of the training. During the training, the participant will receive a copy of the 7711/21 IPC and the IPC/WHMA-A-620 on loan. ETECH-training takes care of the practical materials.

Modules

Modules Title Duration
Module 1 Handling of electronics Contents of the module: - Introduction - Short explanation ESD - Procedures and rules within the EPA (According to IEC 61340) - Handling of electronics (according to IPC-A-610)
Module 2 Working with guidelines Content of the module: - General information about the use of guidelines - Explanation IEC, UL and IPC guidelines - Product class selection (according to IPC/WHMA-A-620) - Terms and definitions according to IPC - Inspection (according to IPC/WHMA-A-620) - Working with the IPC handbooks
Module 3 Preparation of the wires contents of the module: - Stripping of the wire (according to IPC/WHMA-A-620) - Conductor Damage (according to IPC/WHMA-A-620) - Conductor Distortion (according to IPC/WHMA-A-620) - Wire strands Separation (Birdcaging) (according to IPC/WHMA-A-620) - Insulation damage (according to IPC/WHMA-A-620)
Module 4 Soldering of wires and connectors contents of the module: - Soldering General explanation (Wetting, heat transfer, Inter Metallic layers) - Why do we use Flux - Treating the Flux according to J-STD-004 - Soldering alloys tin/lead and lead-free - Care and maintenance soldering - Solder requirements regarding wires (according to IPC/WHMA-A-620) - Solder requirements regarding connectors (according to IPC/WHMA-A-620) - Requirements regarding cleanliness
Module 5 Practice module: Preparing and soldering the wires and connectors contents of the module: - Stripping of the wire - Pre-Soldering/tinning of wires - Different solder wire connections according to procedure 8.1 from the IPC-7721 - Soldering connectors (solder cup connections) - soldering turrets - soldering brackets - soldering to Gaffel Pens - soldering to print tabs - Cleaning of the solder joints (cleanliness)
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