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The increase of electric control systems and installed
ITS technology have resulted in a bigger and heavier wire harness
(often referred to as W/H) which links various W/H components. Under
this circumstance, the need to make the W/H lighter has risen to solve
the problem of over-bloated W/H. Thus, there is an increasing demand
to modularize the wire harness.
This is the backdrop against which the junction block with two major
features- power distribution and efficient wiring - came into existence.
The junction block integrates a power line and a signal line to distribute
power, thereby reducing the number of lines used. Also, efficient
wiring enhances W/H productivity, facilitates assembly operations
of a car, reduces the defect ratio and makes the automation of production
lines easier. The advantages of the junction block have been well
communicated and the product is being introduced to almost all types
of automobiles.
Next phase is the integration of a control unit, utilizing the junction
block. In general, one control unit controls one system. However,
as the control unit is integrated to control multiple systems, redundant
power lines and signal lines can be streamlined. By creating an integrated
unit, fewer components are used, resulting in a wider space available
and less manpower. Therefore, the ripple effect of this method is
expected to be enormous.
In the next generation automobiles, components of the each system
will tend to be more integrated and the modular structure in each
unit will be widely accepted. Apparently, this trend goes beyond the
simple junction block structure or the integration of the control
unit, moving towards sub-modularization of an automobile by each unit.
This will lead to the removal of overlapping circuits such as the
earth circuit, maximizing the lightening effects. Besides, major operations
in which sub modules are assembled will be streamlined, boosting productivity
at the same time.
The basic technologies required to develop and manufacture the junction
block are as follows :
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1. Circuit technology
It is imperative to install an optimal junction
block circuit that matches the circuit of W/H. Numerous advantages
available by the use of the junction will be dependent on how well
the circuit is designed and structured at an initial stage.
2. Product design technology
Junction block is one of the most important
components since it is where power is distributed from and a number
of devices are integrated. The capabilities of the component will
be determined by the concept of the product design. It must have waterproof
and anti-thermal capability to deal with high current. Being subject
to multiple environmental variants, the junction block should be structured
to facilitate its electric functions under various conditions.
3. Design, manufacturing technology for precision
bus-bar injection molding and stamping technology
Bus-bar plays a key role as a basic circuit
in realizing basic functions of the junction block. As bus-bar connects
to the fuse and relay, it becomes a connection point with I/O connector,
determining the electric characteristics. Therefore, the higher level
of precision is required in molding design, molding manufacturing
and stamping of the bus-bar than in any other components.
4. Design, manufacturing technology
for high-precision injection molds and molding technology
Cover type products conceal important components
such as a bus-bar and are assembled with the main body of a car. Final
functions of the junction block would not be fully realized unless
a proper level of strength and precision is guaranteed. In this regard,
design, manufacturing and molding technology of high-precision injection
molds that can satisfy the requirements is a prerequisite for the
right junction block.
5. Design, manufacturing and molding
technology of ultra-precision assembly machine
The assembly operation is the final process
of manufacturing to put together quality reliability of individual
components into a finished product. Since this operation is most vulnerable
to product defects, the sophisticated technology in design, manufacture
and molding of ultra-precision assembly machine is required in order
to create the stable and accurate production systems. KET's production
lines for the junction block are fully automated, with the highest
level of productivity and technology.
6. Total quality assurance technology
and quality management technology
Strict testing is required for a fully functioning
junction. This calls for the capability of checking in advance for
any problems that may arise in an actual situation, through electric,
mechanical, and environmental testing. Thus it cannot be too emphasized
that such role and capability of quality assurance has a direct impact
on the quality assurance of a junction block. In addition, the quality
of products ensured through strict testing must also be secured by
each lot, where the quality management technology constitutes a key
point.
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