1、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
2、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
3、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
4、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W23508X7C5T73308客户已停产项目C195Fiesta2006年底停产CD132MONDEO2007.8停产Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch This document is the property of Lear Corporation.
5、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
6、 consent from Lear Corporation.307Wuhan 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.508Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch This docume
7、nt is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.C5Wuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch This document is the property of Lear Corporation.It cannot be reproduced,delivered,or disclosed to thir
8、d 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 3rd Row遥控钥匙Keyless EntrySwitches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 JBJunc
9、tion 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 Lea
10、r-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
11、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
12、 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 rep
13、roduced,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 Corporat
14、ion.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
15、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 Le
16、ar 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 Corporati
17、on.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
18、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
19、 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
20、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 prope
21、rty 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
22、 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
23、，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
24、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 Co
25、rporation.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
26、 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 Corporation.It 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
27、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 p
28、arties 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
29、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 Corporati
30、on.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,delivere
31、d,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 Corpo
32、ration.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
33、 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 Thi
34、s 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
35、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
36、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
37、 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 T
38、his 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 propert
39、y 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
40、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 t
41、o 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
42、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
43、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
44、 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BK00棕色BN11红色RD22橙色OG33黄色YE44绿色GN55蓝色BU66紫色VT77灰色GY88白色WH99粉色PK-日本车型分类项目数字代码英文代码切线卡VV中间工序工艺卡VV装配工艺卡V电线来料包装VWuhan Lear-DFM Auto.Electric Co.,Ltd CQ Branch This document is the property of Lear Corporation.It cannot be reproduced,delivered,or
45、 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
46、 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 con
47、sent 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 Corporatio
48、n.It cannot be reproduced,delivered,or disclosed to third parties without prior consent from Lear Corporation.一、端子，按结构分为公端子和母端子，端子头部带孔的属于母端子，如方形端子、圆孔端子。尖头端子和片式端子属于公端子；二、公端子插公连接器，母端子插母连接器，并通过对接，实现电路导通。三、环形端子属于特殊端子，一般是用镙栓将它固定在车身上。这类端子有特殊要求。四、端子根据耐温强度不一样，分为普通端子和镀金端子。端子也分不带密封塞端子和带密封塞端子）。五、端子的压接分为自动压接和手动
49、压接；自动压接分为普通端子和密封塞端子压接（部分）；手动压接一般压接密封塞端子和特殊端子（大端子，环端，并接端子等）。带热缩管环形端子普通环形端子最普通端子密封塞端子镀金端子非镀金端子并接端子端子：压接在支路上的金属接触物。八、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 f
50、rom Lear Corporation.一、端子的主要参数：1.导体的压接高度、宽度；2.绝缘层的压接高度、宽度；二、端子导体和绝缘层的压接高度、宽度。使用工具：尖头千分尺测量。三、端子的一个重要特性是拉力值。使用工具：拉力测试仪测量。四、端子的任何一个部位不符合要求，如无毛刷，无窗口，喇叭口过大等，都属于端子变形；五、端子变形和不符合压接参数，都为不合格端子。端子头部（对接部位）端子毛刷端子前喇叭口端子导体压接部分端子窗口（最佳状态：铜丝和绝缘皮各占1/2）端子绝缘皮压接部分端子后喇叭口线束制造讲义端子结构详解线束制造讲义如何识别端子的好坏？1、端子头部变形损坏 This document
