Constructing and assembling cableforms and wiring looms for motorsport vehicles
Overview
This standard identifies the competences needed to construct and assemble various cableforms and wiring looms for motorsport vehicles, in accordance with approved procedures. You will be required to construct and assemble a range of different types and ratings of wires/cables, plugs, sockets and multi-connectors, using a variety of assembly methods and techniques. You will also be expected to use a range of tools and specialist equipment associated with the manufacture and assembly methods, and to check that the assembly has been completed to the level of accuracy and quality required by the specification.
Your responsibilities will require you to comply with organisational policy and procedures for the construction and assembly activities undertaken, and to report any problems with the process that you cannot resolve, or that are outside your permitted authority, to the relevant people. You will be expected to work with a minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.
Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying procedures appropriate to the construction and assembly of motorsport vehicle cableforms and wiring looms. You will understand the construction and assembly methods and techniques used, and their application, and will know about the tooling and ancillary equipment, loom components and consumables, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring that the completed cableforms and looms are to the required specification.
You will understand the safety precautions required when carrying out the assembly and fitting activities. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.
Performance criteria
You must be able to:
- work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
- follow the relevant instructions, assembly drawings and any other specifications
- ensure that the specified components are available and that they are in a usable condition
- assemble the wires and components in their correct positions using appropriate methods and techniques
- secure the components using the specified connectors and securing devices
- check the completed assembly to ensure that all operations have been completed and the finished assembly meets the required specification
- deal promptly and effectively with problems within your control and report those that cannot be solved
- ensure that work records are completed, stored securely and available to others, as per organisational requirements
- leave the work area in a safe condition on completion of the activities, as per organisational and legal requirements
Knowledge and Understanding
You need to know and understand:
- the specific safety precautions to be taken whilst carrying out the activities (including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials)
- the health and safety requirements of the work area and the activities, and the responsibility these requirements place on you
- the hazards associated with the activities, and how to minimise them and reduce risks
- the personal protective equipment and clothing (PPE) to be worn during the activities
- the procedures for obtaining the various types of drawing, job instructions and specifications that are used during the construction and assembly of the cableforms and wiring looms, and how to interpret them correctly
- how to identify the components to be used; component identification systems (codes and component orientation indicators)
- the assembly methods and procedures to be used, and the importance of adhering to these procedures
- how the components are to be aligned and positioned prior to securing, and the tools and equipment that are used
- the various joining, fastening and connecting devices that will be used, and their method of construction and assembly
- the functions of the various wiring looms being constructed
- the types and rating of the various wires and cables, and their functions and application
- methods used to correctly layout the various cables to produce the required cableform or loom (the use of jigs and fixtures, pin boards and templates)
- methods of harnessing the various cables to form cableforms and looms (applying tape, applying corrugated flexible conduit/coverings, lacing cables and applying cable ties at suitable intervals)
- the principles, conventions and wiring regulations associated with motorsport vehicle cableforms and wiring looms
- the consumables, tools and equipment that are used for constructing and assembling the cableforms and wiring looms
- the importance of using the specified cable end fittings for the cableforms and looms, and why you must not use substitutes
- dealing with components or termination devices that are incorrectly assembled, damaged or have other faults
- the quality control procedures to be followed during the assembly operations
- how to conduct any necessary checks to ensure the accuracy and quality of the assembly produced
- how to recognise defects (such as incorrect assembly, ineffective fasteners, component damage)
- the importance of ensuring that the completed cableform or wiring loom assembly is of the correct dimensions and profile/shape
- the importance of ensuring that all tools are used correctly and within their permitted operating range
- the problems with the construction and assembly of the cableforms and looms, and the importance of informing appropriate people of non-conformances
- the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve
- how to access, use and maintain information to comply with organisational requirements and legislation
Scope/range
Scope Performance
Carry out all of the following during the assembly activities:
- obtain and use the appropriate documentation (such as job instructions, cableform/loom drawings, specifications, quality control documentation)
- adhere to procedures or systems in place for risk assessment, hazardous substances, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
- provide and maintain safe access and working arrangements for the loom construction and assembly area
- use safe and approved techniques to construct and assemble the cableforms and wiring looms
- ensure that sub-assemblies and components used are free from damage, foreign objects, dirt or other contamination
- ensure that appropriate policies and regulations are adhered to
- return all tools and equipment to the correct location on completion of the activities
- dispose of waste items in a safe and environmentally acceptable manner
- leave the vehicle cable forms in a safe and appropriate condition and ready for testing
Construct and assemble cableforms and wiring looms for one of the following types of motorsport vehicle:
- single seater
- kart
- rallying
- historic
- sports car
- other specific approved competition vehicle
Select appropriate types and ratings of wire/cables to meet the loom specification, including four of the following:
- single strand
- fibre optic
- screened
- co-axial/tri-axial
- multi-strand
- multiplex
- special insulated
- data transmission cables
- other specific cables
Construct cableforms and looms, to include nine of the following methods and techniques:
- cutting cables to the correct length
- creating suitable breakout points
- soldering sleeves
- wiring harness adhesives (such as duo adhesive)
- cable stripping
- applying cable ties (where appropriate)
- cable termination
- heat shrinking
- cable grouping/routing
- splicing multiple cables together
- binding/taping cables to produce a loom
- using other parts in the cableform/loom (such as moulded components)
- applying polyimide tape when terminating connectors (such as kapton)
- using aramid binding cord prior to using heat sleeves (such as kevlar)
- applying suitable cable identification marks/codes
Construct and assemble motorsport vehicle cableforms and looms, using six of the following:
- cutting device
- fixture
- jig
- measuring device
- wire/cable stripping device
- testing device/meter
- soldering equipment
- computer-aided fault diagnostic device
- heat gun
Terminate wires/cables using five of the following components:
- connectors (multi-contact)
- connecters (crimped)
- cable protection
- connectors (screened)
- plugs/sockets
- connectors (soldered)
- terminal blocks
- other specific termination components
Carry out all of the following checks on the completed cableforms and looms:
- the correct type of cable has been used
- pins in multi-connectors are secure
- cables are correctly routed in the loom and free from kinks
- the cableform or loom is to the correct dimensions
- cable breakout points are in the correct position and to the correct dimensions
- all cable end fittings are of the correct type and are securely terminated
- continuity checks are carried out on all cables and connections
Check motorsport vehicle cableforms and looms comply with one of the following:
- race associations
- legislation, current industry standards, codes of practice and procedures
- vehicle manufacturers specification
- customer standards and requirements
- team/company standards and procedures
- specific vehicle requirements