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Obiectivul cursului:
Insusirea si aplicarea corecta a regulilor de
baza necesare confectionarii cablajelor
auto.
Obiective de invatare:
Cunoasterea alcatuirii cablajului auto;
Cuprins:
1.Flux-ul procesului de productie BMW
2. Cablajul: definitie ; rol;
- partile componente ale cablajului: conductor, terminali,
conector, banda de matisare , componente auxiliare (eticheta,
tuburi, clipuri, protectori, grommet-foaming);
3.Inserarea
4.Matisarea
5.Sudura
6.Inspectie electrica
7.Unelte
8.Plan de asamblare
9.Asigurarea calitatii
10.TPME si 5 S
11.NYS
12.Lucru in echipa
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Testarea
Finish
electrica Torque
Wrench
Control Inserare
sigurante
vizual
Video Test
Clip test
Shrink si Dispach
Welding control
Asamblarea Impachetare
componetelor
Livrare in
Alimentare linie depozit
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2.Cablajul
este “sistemul nervos” al
autovehiculului.
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2.2.Rolul cablajului
Coordoneaza si comanda functionarea intregului sistem de
distributie al autovehiculului;
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Schema de montaj a cablajului pe caroseria
autovehiculului
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2.3. Partile componente ale cablajului:
2.3.1.Conductori
2.3.2.Terminali
2.3.3.Conectori
2.3.4.Banda de matisare
Prescurtarea cablajului:
W/H-Wire Harness
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2.3.1.Conductorul
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Proprietatile conductorului :
a) Culoare:
Initialele culorilor sunt reprezentate de
prima litera a cuvantului din limba germana;
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b)Sectiune: de la 0,17 mm la 35 mm
c)Tipul izolatiei:
amplasati pe masina .
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Tipuri de izolatie:
FLY (-25 ͦ C ÷ 35 ͦ C) = izolatie groasa
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Partile componente:
• Capul terminalului
• Wire-crimp- partea terminalului care asigura
crimpare acestuia pe toroane.
• Izo-crimp- partea terminalului care asigura
crimparea acestuia pe izolatie.
• Siguranta terminalului.
Caracteristici:
• Sunt situati la capetele circuitelor;
• Realizeaza conexiunea electrica;
• Fixeaza circuitul in conector.
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Clasificarea terminalilor
a) Dupa tip:
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Clasificarea terminalilor
Terminali speciali
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o Daca rubber seal-ul lipseste sau este deteriorat, apa patrunde in conector,
terminalul corodeaza si conexiunea este compromisa.
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2.3.3.Conectorul
Este o piesa din material plastic, cu mai multe orificii, care
serveste la conectarea mai multor circuite si realizarea conexiunilor
electrice.
Parti componente:
• Cavitati (orificii)
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Clasificare:
Conectorii se impart in :
Conectori mama
Conectori tata Conector tip tata Conector tip mama
multe feluri:
Conectori cu gel
Module
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Conectori IDC
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POZA CONECTORULUI
Poza specifica cavitatilor conectorilor folosita la inserarea
circuitelor
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Etichetarea
cavitatilor
pe holder
Etichetarea
cavitatilor
pe jigboard
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2.3.4.Banda de matisare: Are rolul de a proteja / izola conductorii si de
a fixa piesele auxiliare (tuburi, clipuri, protectori, grommeti) pe cablajul
auto si o mai buna manipulare a acestuia.
Bandă textilă- nu este impermeabila si se poate rupe prin forfecare. Se poate utiliza
banda de: 19 mm, de 9 mm si 35 mm cu adeziv;
Banda vlies (de lana ) - 19 mm -servește pentru a proteja circuitele de socurile
mecanice;
Bandă PVC colorata – 6 mm - este folosita de operatori in locurile indicate, si ajuta la
montarea precisa a cablajului in matrite la turnarea grommetilor (matisare spot);
Bandă de hârtie – 19 mm - Această bandă este folosită pentru prinderea temporara a
ramurilor, pentru impachetare;
Bandă velur (catifea)
- este folosita pentru a proteja circuitele;
- acest tip de banda nu trebuie sa se suprapuna mai mult de 3 mm;
- se taie cu ajutorul cutitului;
Bandă PVC neagra – 19 mm, este rezistenta la apa, se rupe prin forfecare.
Banda fibra de sticla (mash)- folosita in zona unde se toarna grommet la Foaming.
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Tuburi:
Sunt componente auxiliare ale cablajului cu rol de protectie al
conductorilor.
Sunt confectionate din material plastic care asigura protectie
impotriva temperaturilor inalte sau a socurilor mecanice.
Tipuri de tuburi:
Tub PVC: Protejeaza circuitele impotriva deteriorarilor mecanice, impuritatilor si
umiditatii; . Protejeaza circuitele de temperaturile de la blocul motor - 105 °C, 120
°C, 130 °C, 150 °C;
- Tub taiat
- Tub netaiat
Tub shrink. Protejeaza și izoleaza suduri,circuite creand un spatiu impermeabil;
Tub panzat. Protejeaza cablajul de posibile deteriorari, il face rezistent la abraziune.
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Tipuri de clipuri:
Clip cu strap
Clip bratara
Clip matisabil
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Grommet:
Este un component auxiliar din cauciuc cu rol de etanșare și protecție.
Grommet-ul are rolul de a proteja conectorii, circuitele si terminalii
impotriva umiditatii si a impuritatilor.
Face trecerea de la exterior catre interiorul masinii prevenind astfel patrunderea
umezelii. Pozitia in care urmeaza a fi atasat grommet-ul este indicata in standardul
de lucru si pe jig-board.
In cazul in care prezinta neconformitati, grommet-ul nu va fi folosit deoarece
poate provoca daune multiple.
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Ariile de productie:
Sectia de taiere/preasamblare:
P1&P2 produce toate circuitele și
derivatele pentru zona de
asamblare P3.
Sectia de asamblare: P3
zona în care se realizeaza
produsul final.
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Inserare
Matisare
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Descrierea operatiei:
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2. INVERSIUNE
Se produc scurt-circuite, incendii, accidente foarte grave!!!
3. IZOLATIE DISTRUSA
Poate produce scurt-circuite si chiar incendii, explozii !!!
4. LIPSA CIRCUIT
Nefunctionalitatea unei comenzi ale masinii.
La randul lor terminalii sunt asigurati in mod corespunzator in orificiile lor!
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ATENTIE !
In aria de productie exista legenda si instructiuni pentru
utilizarea fiecarui tip de banda de matisare.
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Matisarea tuburilor
Matisarea locala a tubului: se realizeaza prin trei rotiri de banda pe capatul tubului;
Matisare peste tub si fire: se realizeaza prin 2 ture de banda peste capatul
tubului, 2 ture de banda peste tub si fire si 2 ture de banda peste fire (regula 2-2-2).
Daca diametrul este mai mare, pasul 2 se realizeaza prin 3-4 ture de banda. In cazul in
care spatiul nu ne permite sa rupem banda pe fire, ne intoarcem in 2 rotiri de banda
pe tub.
Matisare peste fire si tub: se realizeaza prin 2 ture de banda pe circuite, se
trage tubul peste matisare, se scoate banda prin taietura tubului si se incheie cu 2
rotiri de banda pe tub.
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Sudura
Definitie:
Sudura este procesul de imbinare a mai multor circuite. Acest proces
este realizat cu ajutorul ultrasunetelor.
Sudura cu ultrasunete:
In acest tip de sudura, prin miscari oscilante (frecare) se obtine o
crestere a temperaturii, circuitele fiind topite obtinandu-se interconexiunea
circuitelor prin presare.
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MATISAREA CLIPURILOR
a) Daca diametrul ramurii sau a trunchiului este mai mic decat latimea clipului, atunci
matisati mai intai firele si prindeti-l prin 3 ture, intinzand bine banda.
matisare de
3 ori
matisar matisare o
e de 3 dată
ori
b) Daca diametrul ramurii sau a trunchiului este mai mare decat latimea clipului, atunci
matisati mai intai o parte a clipului de 2-3 ori, apoi asezati clipul pe fire si fixati-l prin 4-5 ture,
intinzand bine banda.
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Inspectia electrica
Inspectia electrica consta in verificarea conexiunilor si continuitatii electrice a
cablajului, precum si identificarea posibilelor erori (scurt-circuite) sau a unor
componente suplimentare( capace, relee, etc).
Testerul este realizat dintr-o structura metalica pe suprafata careia sunt
asamblate placute din material plastic. Aceste placute contin checker fixtures (CF=
ansamblu mecano- electric cu scopul de a retine conectorul pe perioada de testare a
cablajului electric).
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FOAMING
Foaming-ul este procesul prin care se toarna grommeti direct
pe cablaj. Compozitia grommet-ilor este formata din polyol
( 100 ml ) și izocyanat ( 41 ml ), substante care sunt amestecate
sub presiune si apoi injectate in matrite de catre robot.
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IMPACHETAREA ( PACKING)
Este procesul de pregatirea cablajului principal si a cablajului audio pentru
ambalare.
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2. Asezarea
3. Verificarea cablajului pe masa si
cablajului de catre a ramurilor in 1. Asezarea
inspectorii de protectori protectorilor in
calitate holderele de pe
masa
5. Prinderea protectorilor
de ramuri cu ajutorul
starpurilor
4. Verificarea
cablajului de 6. Prinderea cablajului audio cu
catre inspectorii cel principal prin legatura
de calitate mother- child
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7. Testarea cu
ajutorul programului
conectat la ,masa de
impachetare a
protectorilor si a
clipurilor
10. P
temp rinderea
strap orara ram
harti uri si ben urilor cu
e zi de
11. Asezarea cablajului
compartimentat, in sacul
de ambalare
12. Inchiderea
sacului de ambalare
pentru transport si
emiterea foii de
transport a
cablajului
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Grometii trebuie
Strapurile sa aiba atasate
folosite la protectiile, la
prinderea impachetare
ramurilor, se pentru a evita
strang foarte deformarea lor
bine pentru a
evita desfacerea
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4. Video Test-ul
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Unelte:
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Fata A Jig-board
Fata B Jig-board
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“Multumim pentru
atentie!”
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