As the main operation tool of the wire harness industry, the tooling board plays a decisive role. Employees need to rely on the tooling board during back-end assembly operations. It can be said that the tooling board is the basis and basis of the operation. Its layout layout and graphic information are directly related to production efficiency / product quality. It can be said to be a three-dimensional and intuitive Operating instructions! Now let us understand the tooling board through the following questions.
Tooling board is an auxiliary production tool, the purpose is to produce automotive wiring harness to meet customer needs, what is customer demand? That is the 2D drawing of the wiring harness. Usually we call it the customer drawing. It is a drawing drawn by the harness engineer according to the electrical and electrical layout of the vehicle. There are connectors and wires and specific requirements for various auxiliary materials, such as the insertion holes of the wires. Basic information such as the color of the wire and what tape to fix.
The tooling board is converted into design drawings suitable for the production of employees according to the requirements of the customer's drawings, and then such drawings are manufactured on the wooden board, so that the employees can intuitively understand the familiar operating requirements; because the information on the tooling board is more complicated (Germany American Departments of Japan are different), new employees can only be mastered through qualification training.
2. Composition of tooling plateThe tooling board is generally composed of wooden boards (substrate) and various fixtures (metal / plastic). Because of the need to carry a lot of fixtures (heavier weight), the wood board is generally solid, and it is arranged at an angle to the employees. There are two production modes: assembly line and veneer. There are many pictures and even physical photos of parts on the tooling board, which is to make employees more clearly understand the requirements of manufacturing.
First of all, the tooling board must be manufactured according to the customer's drawings, and the dimensions required by the customer drawings must be guaranteed; the customer drawings have tolerances, such as from connector A to staple B, the drawing requirements are 115mm +/- 10mm, then, to ensure quality, usually The center value is 115mm when manufacturing the tooling board. If it is found that the position of the sheet metal hole is farther than the staple by 7mm when loading the car, then we need to go to the public 115 + 7 = 122mm at this time.
At this time, the position of the lower nail fixture can be moved to ensure that the length of the branch is basically about 122mm.
Secondly, tooling boards require foolproof measures. For example, there are staples and rubber parts required by the direction. The foolproof fixture means that it is impossible to put it in the fixture if the opposite direction is used, so that employees will naturally know.
Third, the tooling board needs to be released, and the first wire harness (preferably high-quality) is generally made for verification. This work is led by the Quality Department. It is carefully checked in accordance with the customer ’s drawings. Any problems that do not conform to the drawings can be raised. During this process, the Production Department can also propose requirements for easy operation and comprehensively consider improvements; If you need to change the branch direction and size of the revised PA car, according to the normal process, you need to do sample line verification first, and IE / quality / production will participate in the first piece release.
4. Development trend and new technology of tooling boardA. In March 2017, the Shanghai Munich International Electronics Show demonstrated an electronic tooling board that uses an electronic screen as a substrate instead of a wooden board. The entire tooling board is a large electronic screen. The branches above are not drawn on the board, but are displayed on the screen with electronic program control. In this way, if there is a change, only the background program needs to be adjusted to import the changed electronic layout. It can be displayed clearly in the database, avoiding the work that required a lot of time and effort to paste the cut patch in the past. However, because it is an electronic screen, the above fixtures often only retain the critical path, and may only be suitable for relatively simple wiring harnesses. In general, if the cost can be effectively controlled, the development prospects are worth looking forward to.
B. The principle of the automatic punching machine for tooling board is very simple. Similar to the SMT machine in the traditional electronics manufacturing industry, only the coordinates that need to be punched need to be entered into the machine. The drill bit (with different diameters) that comes with the machine will automatically punch the hole. You only need to install the fixture by hand. This machine saves the time and effort of manpower drilling and greatly improves the efficiency and shortens the construction period when manufacturing tooling plates in large quantities (new projects or large-scale changes). If the cost can be controlled well, I believe that there is huge room for development.
The tooling board is the most important carrier for the production of wire harnesses. It can be used more effectively with less effort, and there are many places worth studying and exploring.
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