A standardized method for measuring the force required to join wire harnesses and sparkplugs

Understanding the forces required to insert a sparkplug wire (wire) onto a sparkplug (plug), independent of worker variation, is important for ergonomists, engineers, and designers. This paper describes a methodology for measuring the forces required to seat a wire onto a plug. A three-axis programmable mill was used to insert wires onto plugs mounted on a force transducer. Inflection points and slopes of the force–displacement curves were found to correspond to mechanical events as the plug and wire were joined. These events were further isolated by dissecting the wires to better understand the force contribution of each wire component. Liner superposition was then used to show that each of these force elements may be added to estimate the total force required to seat a wire onto a plug. This methodology may be used to quantify the effects of design choices, lubricants (wet and dry), and pre-working on axial insertion forces associated with sparkplugs and other insertions. This paper does not address worker abilities or variation, however, the methodology and equipment described may provide a foundation for the exploration of worker ability, variation and work techniques.