Cable and Wire Harness Assembly Handbook Ground .IPC Midwest September 2008 Cable and Wire Harness

  • View

  • Download

Embed Size (px)

Text of Cable and Wire Harness Assembly Handbook Ground .IPC Midwest September 2008 Cable and Wire Harness

  • IPC Midwest September 2008

    Cable and Wire Harness Assembly Handbook Ground Rules: 1) Why do we do what we do 2) Technical History 3) Some How, but only for that which SHOULD not be in the standard 4) Further explain the processes already in the standard 5) Lessons Learned to be as part of each section it applies to. 6) Not be a J/STD-001 or A-610 book, more like the A&J Handbook or Conformal Coating but referencing back to the standard to

    see the end results. 7) Structure to follow TECHNOLOGY 8) Include ancillary technology. 9) Audience WIRE AND CABLE MANUFACTURES and others who are craving information, Designer, ME, QA, Assemblers. 10) This is stand alone with the A620. 11) If the Information for a section resides in another document its OK to reprint into this document. Must add statement that if

    they want to learn more than what is applicable to this document you see the base reference. 12) Always think about new technology insertion 13) Pb-Free issues. 14) Include basic material types and use selection information in each section. 3 TYPES OF HARNESS (INFO FOR INTRO SECTION) Type 1 - Unprotected Harness No overbraiding, jacketing etc, held together by lacing/ties Type 2 - Protected Harness Has Jacket/Cloth overbraiding, no overall shielding Type 3 - Protected/Shielded Harness Jacketed/Cloth overbraid and overall shielded

  • IPC Midwest September 2008

    TABLE OF CONTENT for IPC-HDBK-620 1 Cable and Wire Harness Assembly Handbook $Scope $Purpose $Approach To This Document $Uncommon or Specialized Designs $Terms And Definitions #Shall or Should #Classes of Product #Document Hierarchy #Tool and Equipment Control #Observable Criteria #Defects and Process Indicators #Inspection Conditions #Measurement Units and Applications #Verification of Dimensions #Visual Inspection #Contamination #Materials and Processes

    Subjects marked with $ are to be looked at and where necessary expand or explain the category. Those subjects marked with # will be rewritten to agree with actual handbook use and ground rules. Teresa Rowe?

    Covers Section 1

    2 APPLICABLE DOCUMENTS IPC STAFF Covers Section 2 3 Cable and Wires Layout and Length measurement

    wire measurement termination type measurement points and

    process strip allowances. wire types and selection of (important)

    Brett Miller USA Harness John Laser L3

    Covers Section 11

    4 Wire Preparation Stripping Tinning

    Richard Rumas Honeywell Covers Sections 3, 4, 13.1

    5 Wire Termination Methods a) Mechanical Crimp Terminations (Contacts and Lugs) Insulation Displacement Connection (IDC) b) Thermal Splices (including hot air melt) Soldered Terminations (solder cups, turret,

    pierced, J-Hook) c) Other Technology Ultrasonic Welding Wire Wrap d) Coaxial and Twin Axial Cable Assemblies

    Subsection & Author a)Richard Rumas Honeywell d))John Laser L3 c)Brett Miller USA Harness b)Teresa Rowe ????

    Covers Sections A) Section 5, 6, 8 B) Section 4, 8 C) Section 7, 18 D) Section 13

    6 Connectorization Richard Rumas Honeywell Covers Sections 9, 13 7 Molding/Potting Brett Miller USA Harness

    Gordon Sullivan Covers Section 10

    8 Marking/Labeling Les Bogart Bechtel Covers Section 12 9 Securing

    Lacing tape vs plastic types knots, anti-knot loosening location of ties, use of lacing tape as securing of tapes and sleeving

    Randy McNutt - Northrop Covers Section 14

    10 Harness/Cable EMI/RFI Shielding EMI/RFI shielding theory methods of shielding shield jumpers [with how to of using shrink

    sleeves in wire term methods/splices)

    John Laser L3 Covers Section 13, 15

  • IPC Midwest September 2008

    11 Harness Jacketing Methods Mechanical Braiding (discussions of machines

    and braiding materials). Open loose Sleeving Closed Sleeving Tapes

    Randy McNutt - Northrop Covers Sections 15, 16

    12 Finished Assembly Installation wire routing rules box installations rules hardware termination Terminal Blocks clamping ESD caps

    Les Bogert Covers Sections 14, 17

    13 Measurement/Testing Les Bogert Section 19 14 METHODS OF STD REPAIR & MODIFICATION

    (proposed) On Hold NEW

    APP A A-620A to this HDBK pointer Chart Leadership prior to publishing

  • 1-1

    This handbook is a companion reference to and was prepared using IPC/WHMA-A-620A. Format of this Handbook The section and paragraph numbers in this handbook refer and correspond to the section and paragraph numbers in Revision A of IPC/WHMA-A-620. Where used verbatim, text of IPC/WHMA-A-620 is identified by being boxed. Foreword 1.1 Scope The scope of the IPC/WHMA-A-620A provides visual, electrical and mechanical acceptability requirements. This document can be used by manufacturers or as a stand-alone for purchasing products. Activities such as in-process and end product inspection are not defined in the document. 1.2 Purpose This document does not address assembly methods. 1.3 Approach to This Document The document is organized such that the title of each section includes the criteria for that topic. In some cases, the same or similar figures are shown throughout the document, and the user is advised to select the correct section when reading the document. When product is compliant to Class 3, the manufacturers are required to use a documented process control system. Documentation may occur in any format compliant with a users internal requirements. For all Class 3 product and where a document process control system is used for Class 2, process control and corrective action limits are required. There is no requirement for Class 2 to have a documented process control system, however when one exists, these additional requirements apply. The focus in this section is on the process control. As stated in the document, there is no requirement for a statistical process control system. The concern is about managing the processes to produce hardware that meets the requirements. The user may decide that statistical process control is necessary for a particular situation, and in these situations, they may select this as the type of process control system to use. Class 2 and Class 3 manufacturers are required to use process control methodologies in the planning, implementation and evaluation of the processes. Unlike the earlier requirement in this section that may result in documentation depending on the product class, the approach to using process control methodologies is more of a technique used to achieve an end result. 1.4 Shall or Should The word shall is used throughout the document for mandatory requirements. In some cases, the requirement is applicable to all classes as a process-related requirement, but in some cases, the requirement is not applicable to all Classes. In each case, a text box with the associated requirement is listed near the paragraph in which the word appears. Each Class requirement is stated in the text box, and the user will select the appropriate class to determine whether a hardware defect exists for the relevant product. Conditions such as Defect, Process Indicator, Acceptable and Not Established could be stated in the text boxes. Where the condition is Acceptable, no further action is required by the user when the condition exists. Where the condition is Not Established, the document does not provide any criteria. If a condition exists where the criteria is Not Established, the user is encouraged to determine if additional action is necessary for the particular product. Where it is used, the word should is providing guidance to the user. Even though no requirement exists, the document developers provide this as useful information to the users. 1.5 Uncommon or Specialized Designs The document developers recognize that industry consensus documents typically address common technologies. There may, however, be times when the user needs to have additional requirements definition for particular applications. Users are encouraged to develop these additional criteria for their application and to include the definition for acceptance of each characteristic. Users are also encouraged to provide this information, where feasible, to the IPC Technical Committee for consideration in future revisions of the document.

  • 1-2

    1.6 Terms and Definitions Definitions for some of the terms used in the document can be found in the Terms and Definitions section of the standard or in Appendix A of the standard. 1.7 Classes of Product The product classes are provided in this section of the standard. Definition of the product class is necessary in order to determine which requirements are applicable. The standard provides guidance to the manufacturer where the manufacturer and user have not established the product class requirements. In these situations, the manufacturer is permitted to select the product class. 1.8 Document Hierarchy There are many documents that may be invoked when manufacturing this product. The document hierarchy or order of precedence is established in this section of the standard. There are various standards available to the industry that include topics also discussed in the IPC/WHMA-A-620A, including J-STD-001, Requirements for Soldered Electrical and Electronic Assemblies and IPC-A-610, Acceptability of Electronic Assemblies. IPC/WHMA-A-620A users are not required to use these documents unless contractually required. Although information provided may appear to be similar, the documents have different scope statements and conflicts with the requirements of IPC/WHMA-A-620A may be introduced it the documents are used incorrectly. The user does have the option to select alternate acceptance criteria. Where such criteria are specified, however, procurement documentation