Cable and Wire Harness Assembly Requirements Flashcards
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Read the first 7 Cable and Wire Harness Assembly Requirements flashcards as text
When a harness assembly requires a 'pigtail' splice, which IPC/WHMA-A-620 requirement applies to the splice insulation?
Answer: The splice must be covered with approved insulation material
IPC/WHMA-A-620 requires all splices, including pigtail splices, to be covered with approved insulation materials such as heat-shrink tubing or splice caps.
What condition is described as 'birdcaging' in a wire harness assembly?
Answer: Flaring or unwinding of stranded wire strands away from the conductor axis
Birdcaging occurs when stranded wire strands separate and flare outward from the conductor axis, resembling a birdcage, often caused by improper handling during stripping.
Per IPC/WHMA-A-620, what is the maximum number of conductors permitted in a single crimped ring terminal for a Class 3 application?
Answer: One conductor only
For Class 3 assemblies, ring terminals are generally intended for a single conductor unless the drawing specifically allows multiple conductors in a multi-wire terminal.
What does the 'pull-force test' verify in a wire harness assembly?
Answer: That crimped or soldered terminations meet minimum retention force requirements
A pull-force test applies a specified tensile load to a terminated wire to verify that the crimp or solder joint meets the minimum force retention requirement per the applicable standard.
When routing a cable harness near a heat source, what is the primary protective measure required?
Answer: Maintaining the minimum separation distance or using rated insulation specified in the drawing
Engineering drawings specify minimum clearances from heat sources or require use of high-temperature rated insulation, and assemblers must follow these specifications.
In IPC/WHMA-A-620, what is meant by the term 'workmanship standard' as applied to cable assemblies?
Answer: A documented set of acceptance and rejection criteria for assembled products
A workmanship standard defines measurable accept/reject criteria for finished assemblies, ensuring consistent quality regardless of who performs the assembly.
Which type of splice is generally preferred for high-vibration environments in cable harness assemblies?
Answer: Crimped inline splice with heat-shrink sleeve
Crimped inline splices with heat-shrink sleeves provide superior mechanical integrity and vibration resistance compared to soldered or twist-and-tape methods.