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A wire harness, often referred to as a cable harness or wiring assembly, is a systematic and integrated arrangement of cables within an insulated material. The purpose of the assembly is to transmit signal or electrical power. Cables are bound together with straps, cable ties, cable lacing, sleeves, electrical tape, conduit, or a combination thereof. The wire harness simplifies the connection to larger components by integrating the wiring into a single unit for &#;drop-in&#; installation.
Wire harnesses are often confused with cable assemblies however, the two are quite different. The main difference is that a cable assembly normally has only two ends, whereas a wire harness contains multiple breakouts (ends) that run in many different directions with multiple terminations on each breakout.
Wire assemblies are most commonly used in the transportation industry, including automobiles, buses, trucks, and planes. Construction machinery, industrial equipment, electronics and white goods (household appliances) will also be constructed using wire harnesses.
Decreased installation time: Many vehicles require miles of wiring in order to operate. A wire harness assembly process greatly simplifies the manufacturing of these vehicles by integrating all the wires and cables needed into a single apparatus. The installation then becomes a simple matter of &#;dropping in&#; the harness, rather than running all of the wires individually.
Security and safety: When wires and cables are bound within a single harness, the individual components are more secure against the adverse effects of vibrations, abrasions and moisture. Space is optimized and the risk of an electrical short is reduced because the wires have been constructed into a non-flexing bundle. The risk of electrical fire is also reduced when the wires are bound within a flame-retardant sleeve.
A wire harness process is designed based on the geometric and electrical requirements of the equipment it is to be installed in. Once the initial design is established, a schematic is used to create the manufacturing paperwork and the assembly board for the harness. The assembly board, also called a pin board, is a full-size diagram of the harness which shows all of the components and their locations. It also serves as the workbench for the harness.
The wires needed for the harness are first cut to the desired length and labeled appropriately. Next, the ends of the wires are stripped to expose the uninsulated conductor and fitted with any required terminals or connector housings. The wires and components are then assembled on the pin-board to the desired specification and then bound together.
Wire harness assembly process is one of the few remaining manufacturing processes that is more efficiently done by hand, rather than automation. This is due to the variety of processes that are involved in the assembly. These manual processes include:
Because of the difficulty involved in automating these processes, manual production continues to be more cost-effective, especially with small batch sizes. This is also why harness production takes longer than other types of cable assemblies. Production can take anywhere from a few days to several weeks. The more complicated the design, the longer production time is required.
However, there are certain portions of pre-production that can benefit from automation. These include:
The final step of the assembly process is to test the harness for electrical functionality. This testing is done with the aid of a pre-programmed test board. The test board is programmed with the required electrical characteristics and the completed harness is then plugged into the board and checked for faults.
Hopefully, this blog has answered most of your questions regarding wire harness assemblies. If you are wondering if custom wire harness might be right for you. Look no further, we&#;ve got the answers you need.
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The History of Wire Harnesses
In the &#;s, wire harnesses became more prominent. Especially in the automotive industry.
Engineers found that binding the many wires and cables into a wire harness allowed the wires and cables to be better secured.
This securing was against the adverse effects of :
Also, the &#;s saw a boom in electrical household goods.
All of these goods included many small components.
They also had connections by complex individual wiring systems.
Some of these household items included:
Manufacturing these products for mass production was often timely as well as costly.
Therefore, manufacturers offered a more timely and cost effective build.
This introduced preassembled wire harnesses.
Wire Harnesses are an assembly of cables or wires that have been bonded. These assemblies distribute electrical signals in the most efficient way possible.
Certain items used to bond Cables and Wire Harnesses include:
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Engineers design Wire Harnesses according to specific electrical requirements.
A diagram or drawing is then provided for the assembly.
Typically the manufacturing of wire harnesses is produced by hand.
This is due to the involvement of many different processes, such as:
Wire Harnesses play a critical role with any electrical device.
As a wire harness manufacturer since , we can attest first hand it takes tremendous skill and experience to perform these tasks at high levels.
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