Cable and Wire Harness Assembly Requirements Flashcards

What is the correct action when a technician discovers a wire with damaged insulation midway through harness assembly?

Answer: Stop assembly, quarantine the part, and initiate a nonconformance report

Discovering a defect during assembly requires stopping work, quarantining the nonconforming part, and initiating a formal nonconformance process per quality management requirements.

What is the purpose of 'continuity testing' as the final electrical test step for a wire harness assembly?

Answer: To verify that every electrical path is complete and no shorts or opens exist

Continuity testing verifies that each wire path is complete (no opens) and that no unintended connections exist between nets (no shorts).

Per IPC/WHMA-A-620, what condition requires the use of a ferrule on a stranded wire before insertion into a screw-clamp terminal block?

Answer: When the terminal block manufacturer or engineering drawing specifies ferrule use

Ferrule use is required when specified by the terminal block manufacturer's instructions or the engineering documentation, not universally mandated for all stranded wire applications.

What is the function of a 'shield termination' in a shielded cable harness assembly?

Answer: To provide a low-impedance path connecting the cable shield to a ground reference

Shield termination connects the cable's braided or foil shield to the circuit ground, providing a return path for induced currents and reducing electromagnetic interference.

When installing a grommet in a panel cutout for a wire harness, which condition indicates a proper installation?

Answer: The grommet seats fully in the cutout and retains the wires without sharp-edge contact

A correctly installed grommet must fully seat in the cutout opening and protect wire insulation from contact with the sharp edges of the panel.

What does 'AWG' stand for and how does it relate to wire selection in harness assemblies?

Answer: American Wire Gauge — a standardized system where higher numbers indicate smaller wire diameter

AWG (American Wire Gauge) is a US standard for wire sizing where counterintuitively, higher gauge numbers correspond to smaller wire diameters and lower current capacity.

In the context of IPC/WHMA-A-620 inspections, what does the term 'target condition' describe?

Answer: The ideal desired result that represents perfect workmanship

A target condition in IPC/WHMA-A-620 represents the ideal manufacturing result — the best possible outcome that all assemblers should strive to achieve.