线束工艺讲解.pptx

单击此处编辑母版标题样式,单击此处编辑母版文本样式,第二级,第三级,第四级,第五级,2016/3/4,#,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,线束制造讲义,目录,第一章：汽车基础知识,第二章：汽车线束简介,第三章：线束制造材料,第四章：线束制造方法,第五章：制造作业文件,第六章：线束生产方式,第七章：线束制造工装,第八章：线束制造流程,第九章：,线束制造质量控制,第十章：,不合格品处理,第十一章：,其它,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,线束制造讲义,第一章：汽车基础知识,（一）小 汽 车 分 类,（二）工厂及客户车型介绍,（三）整车图片展示,（四）车身布局示意图,（五）轿车用关联制品,（六）线束的布局,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,小汽车,根据车体外形结构,线束制造讲义,（一）小 汽 车 分 类,AT,：自动档,根据换档模式,MT,：手动档,三厢（,4,门）：有独立的行李箱,根据功能配置,中配,高配,对应市场,销售定位,两厢（,5,门）：可通过后备箱进入,车体，俗称尾门。,低配,标准型,舒适型,豪华型,此外，汽车根据发动机的排量大小，可分为,1.3L,1.6L,1.8L,2.0L,2.4L,2.5L,3.0L,等，一般来说，排量越大，耗油量也,会越大，动力输出也越强大。另外，,汽车的车载电压为,12,伏,。,分类,项目,车型代码,英文名称,备注,公司当,前部分量产车型,W23,508,X7,C5,T73,308,客户已,停产项,目,C195,Fiesta,2006,年底停产,CD132,MONDEO,2007.8,停产,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,线束制造讲义,（二）工厂及客户车型介绍,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,307,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,508,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,C5,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,UGDO,视听娱乐系统,Infotainment,后座娱乐系统,Rear Seat Entertainment,第三排座椅电动折叠,Power Folding 3,rd,Row,遥控钥匙,Keyless Entry,Switches,双向遥控,Car2U,感应门系统,Passive Entry,开关,Immobilizer,防盗,Body Electronics,车身电子,TPMS,胎压监测,High Voltage EDS,高压电路分配系统,TV Receiver/Audio Amp,电视广播接收,智能中央控制盒,Smart JB,Junction Box,中央控制盒,Wiring,线束,线束制造讲义,（四）车身布局示意图,车库门开启,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,线束制造讲义,（五）轿车用关联制品,信息记录仪,压力传感器,线束,保险丝盒,其他部品,为我们生产,的产品,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,线束制造讲义,（六）线束的布局,前车线和发动机线的布局图,线束是连接轿车电气系统的血管和神经,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,门线,门线,门线,门线,后门线,车顶蓬线,侧安全气囊线束,侧安全气囊线束,发动机线,M/,B,后车身线,J/B,前车线,仪表盘线,油箱线,主线束,线束制造讲义,线束在车身的平面布局,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,线束制造讲义,第二章：汽车线束简介,（一）线束的概念及组成,（二）线束的分类,（三）线束成品展示,（四）线束在车身的装载状态,（五）线束装车实图,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,线束制造讲义,（一）线束的概念及组成,线束的概念：是指实现汽车所有功能配置的,电路系统的组合，因为是将一根根的电线捆绑成,束，故称线束。,线束主要由,“,连接器、支路（含端子）、定位,夹、胶带缠绕,等,”,组成，,线束在汽车构成中占重要,地位，质量要求高。,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,线束制造讲义,（二）线束分类,发动机线束：,ENG,主线束,小线束,目的：易于后期,保养或修理,世界上大多数国家实行,左驾,，,包含中国大陆及台湾、美国、,俄罗斯等。只有极少数国家实,行,右驾,，如中国香港、澳门、,英国、日本、印度等。,中央线盒线束：,JB,仪表板线束：,IP,座舱线束：,BODY,驾驶侧门,门线束 乘客侧门,电瓶线束 左右后门,顶蓬线束,行李箱线束,倒车雷达线束,ABS,刹车线束,接地线等,汽,车,线,束,门线束（小线束）,仪表板线束（大线束）,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,发动机线束（大线束）,中央线盒线束（大线束）,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,线束制造讲义,（三）线束成品展示,仪表盘（,IP,）,发动机室（,ERM,）,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,地板,(,车身,)Floor,门（,Door,）,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,线束制造讲义,（四）线束在车身的装载状态,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,线束制造讲义,（五）线束装车实图：,C307,发动机线束装配图,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,线束制造讲义,第三章：线束制造材料,（一）连接器,（二）定位夹,（三）护套,（四）管子,（五）胶带,（六）电线,（七）支路,（八）端子,（九）铰接点,（十）其它,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,线束制造讲义,一、连接器,1,、连接器的定义：指线束上的每一个连接插头。,2,、连接器分类：,连接器,公连接器,:,插接公端子,外形结构,母连接器,:,插接母端子,密封性能,防水连接器,普通连接器,防水连接器,:,大部分插接密封塞端子,小部分插接普通端子,.,普通连接器,:,插接不带密封塞的普通端子,公连接器,母,连,接,器,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,线束制造讲义,3,、连接器结构：锁止片、密封圈、对接锁止机构，支架，,盖子，定位夹等。,普通连接器,连接器结构部位图解：,防水连接器,母端子,母连接器本体,母连接器锁止片,公连接器锁止片,公连接器本体,公端子,锁止机构,母连接器本体,母连接器密封圈,母连接器锁止片,连接器对接锁,止机构,公连接器锁止片,母连接器密封塞,公连接器本体,母连接器端子,公连接器端子,公连接器密封塞,连接器对接,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,线束制造讲义,4,、连接器各部位功能,4-1,锁止片：对连接器内的端子进行二次锁止。,连接器锁止片只有在开启状态才能插入端子。,4-2,密封圈：对防水连接器进行密封。,4-3,定位夹：固定连接器到车身装配位置。,4-4,支架或拉杆：连接器辅助安装。,4-5,盖子：保护电线，保证连接器的安装方向。,4-6,对接锁止机构：保证对接连接器正常对接锁止。,4-7,短路片：保证连接器电路功能实现。,4-8,除以上结构外，个别连接器还有,铁卡扣,等辅助安装机构。,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,线束制造讲义,5,、连接器的基本特征,1,、大多数连接器的孔位附近均标有孔位号，标示位置有可能是连接器正面，也有可能是连接,器的底部。,孔位号多数用“数字”表示,只有少数用“字母”表示。如图：,2,、普通连接器的孔位一般为方形，且带有,导向槽,，可根据连接器孔位结构识别端子的大致结构。,端子导向槽,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,线束制造讲义,3,、防水连接器的孔位多为圆孔，所以端子通常都带密封塞，只有极少部分因为连接器自带密封，,而端子不需要带密封塞。,防水连接器的空孔需要用堵头或堵棍进行密封,。,堵头,堵棍,通常：堵头或堵棍都是先在线下进行预装，再插支路端子。,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,321691933,防错槽如图,F7RB-14A464-AA,防错槽如图,线束制造讲义,4,、连接器绝大多数均带有防差设置，以避免连接器错装。但相同相似外形的连接器很多，需要在,操作时，学会识别防差部位，防止用错连接器。,防错槽不同,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,左图是航空连接器实例，我在客户处了解到的情况是，航空航天连接器都是自带端子、金属外壳、也没有很多的分离附件。,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear CorporationIt cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,连接器上的定位夹,（需要预装）,通常我们将定位夹和扎带都俗称为扎带。,线束制造讲义,二、定位夹、扎带,定位夹：装配在线束上，并固定线束到车身上的卡子。,定位夹外形各异，可分为,带扎带,和,不带扎带,两种。,带扎带的定位夹,扎带：不带定位夹的纯粹的扎带，,主要用于捆绑线束或者连接器盖子。,不带扎带的定位夹,还有一种特殊的定位夹，只需要,直接安装到连接器上即可。,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,小护套,大护套,线束制造讲义,三、护套,护套：线束在装车过孔时用到的一种防水密封橡胶件。,可分为,“,小护套,”,和,“,大护套,”,，主要功能为防水。所有,护套均为,“,闭口,”,型。,护套也有国产和进口之分，进口护套相对国产护套,质量较好。,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,线束制造讲义,四、管子,管子属于线束上的覆盖物，根据耐温强度不一样，包含,PVC,管、,PU,管、,波纹管、纤维网管、泡沫管、硬质管等，并分为开口管和闭口管。管,子的大小用管径表示，管径越大，管子越粗。,各种管子图解：,特征：表面光滑，冬季较,硬，长时间放置易脆断。,有开口和闭口之分。颜色,多为黑色。,PVC,管,线束制造讲义,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,PU,管,开口,PU,管,闭口,PU,管,特征：表面光滑，材质较柔软，使,用寿命较,PVC,管长。有开口和闭,口之分。颜色多为黑色。,线束制造讲义,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,编织带,特点：,具有良好的伸缩性、耐磨性,，,保证线束柔软。,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,线束制造讲义,波纹管,特征：表面呈波纹状，有开口和闭口之分，颜色,多为黑色，部分开口波纹管的管口较为锋利。,Wuhan Lear-DFM Auto.Electric Co.Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,线束制造讲义,纤维网管,特征：化学纤维编织物，表面光亮。,功能：耐高温。,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,线束制造讲义,毛毡,特征：主要应用于,汽车座舱、门板、仪表,盘、门线束上，,起到耐磨、抗温、减震、降噪等作用。,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,线束制造讲义,五、胶带,胶带：线束表面的覆盖物，用以保护线束。根据耐,温等级和材质不同，可分为：,PVC,、羊毛、棉质、聚,酯、防水、泡沫、无胶、纸胶带、加棉胶带等。,胶带规格有,9mm,、,12mm,、,19mm,、,25mm,、,50mm,等,最主要,的规格为,12mm,19mm,。胶带颜色众多，有黑色、白色、,绿色、红色、黄色；彩色胶带一般用做标识。,线束制造讲义,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,胶带图解,19MM PVC,黑色,9MM PVC,黑色,PVC,胶带,19MM PVC,白色,12MM PVC,黑色,12MM PVC,白色,特征及用途：,表面光滑，适用普通线束表面缠绕。,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,线束制造讲义,羊毛胶带,特征及用途：,胶带表面呈羊绒状，具有防噪，抗干扰的作用。,主要用在顶蓬线束和收音机线束分支上。,19MM,羊毛胶带,9MM,羊毛胶带,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,线束制造讲义,棉质胶带,19MM,棉质胶带,特征及用途：,胶带表面无绒状，与电工胶带相似。,具有耐磨的作用，用于易于摩擦的线束分支。,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,线束制造讲义,聚酯胶带,19MM,聚酯胶带,特征及用途：,胶带表面平整，无细纹和光泽，手工不易撕断。,具有耐高温的作用，主要用于发动机线束分支上。,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,线束制造讲义,防水胶带,50MM,防水胶带,特征及用途：,胶带表面光滑，宽度为,45-50MM,。,主要用于不具有防水要求的铰接点焊点覆盖。,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,线束制造讲义,泡沫胶带,特征及用途：,泡沫发泡物，单面有胶，粘于油性纸上面。,有隔音和防噪的作用，广泛用于仪表板和门线束。,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,线束制造讲义,无胶胶带,25MM,无胶胶带,特征及用途：,胶带表面光亮，无粘性。,主要作用是易于线束返修，广泛用于日本车型。,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,线束制造讲义,纸胶带,9MM,纸胶带,特征及用途：,胶带表面呈纸状。,纸胶带一般用于回折支路和线束成品包装。,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,线束制造讲义,六、电线,一、电线由线型、线径、颜色三部分组成：,线型,：通常指电线的耐温等级。根据不同地区的汽车标准体系，可分为,WA,（,105C,），,WK,（,125C,），,WE,（,150C,），,HJ,，,AVS,，,AVSS,，,AVF,，,R2B,等。不同线型的电线之间，绝缘皮厚度会有所不同。,线径,：指单根铜丝的截面积之和。有,0.35,，,0.50,，,0.75,，,0.85,，,1.0,，,1.25,，,2.0,，,4.0,，,6.0,，,10.0,，,15.0,，,25.0,等。不同线径的电线具有不同的铜丝股数和绝缘皮外径。线径的大小决定电线的粗细。,颜色,：指电线绝缘皮的颜色。电线的颜色主要分为主辅色,”,和,“,单色,”,两种，通常用数字来表示电线的颜,色。具体的颜色及表示方法见下页。,一个完全的电线零件号，如：,WA 0.50 76 AVSS-0.35-90,二、电线有一种特殊的，叫屏蔽线（屏蔽丝），主要作用是抗干扰。,颜色,英文代,码,数字代,码,示例图片,备注,黑色,BK,00,棕色,BN,11,红色,RD,22,橙色,OG,33,黄色,YE,44,绿色,GN,55,蓝色,BU,66,紫色,VT,77,灰色,GY,88,白色,WH,99,粉色,PK,-,日本车型,分类,项目,数字代码,英文代码,切线卡,V,V,中间工序,工艺卡,V,V,装配工艺,卡,V,电线来料,包装,V,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,线束制造讲义,电线的颜色体系及应用,代码所用之处,电线,主辅线,（双色线）,主色：色多,辅色：色少,单色线：单一电线颜色,主辅线颜色示例：,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,线束制造讲义,七、支路,支路：经过切线机切割压端子的电线，便称为支路。,每一根支路都有一个支路号,支路号通常用数字和字母,混合组成，如,8GB8,。,在上线操作时，以支路号为基础进行。,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,支路的存在方式分为：,1.,单支路（两端压端子）。,2.,铰接支路（一端压端子或者无端子只剥皮参与两个铰接点的铰接）。,3.,并接支路（两根或多根支路并接一个端子）。主要有,2-3,根支路。,4.,绞线支路（两根或多根支路通过绞线机绞在一起，,33-55,个绞花,/,米，在端,子尾部,50MM,处用,PVC,点缠）。俗称麻花线。,线束制造讲义,支路的存在状态,铰接点,单支路,并接支路,麻花线,线束制造讲义,Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch,This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.,一、端子，按