Wire harnesses are assemblies of electrical cables used for transmitting signals and power. They are typically essential in making electronics more durable and efficient. But what exactly is a wire harness? What are the components of a wire harness? Here are some ways to identify a wiring harness.
Terminals: Wiring harnesses contain several connectors, some of which are more common than others. Some have insulation, while others are not. Connectors consist of many materials, including wire, tubing, or metal.
Wire harnesses should consist of metal and rust-resistant coating material. Copper is a popular conductor, but it can be prone to corrosion. Coatings are often essential to prevent this. Connectors attach the wires; some permanently attach, while others are temporary.
Outsourcing wire harness assembly is an excellent option for companies with insufficient manpower to produce the components. Contract manufacturers are often more efficient since they can use a single piece of equipment for many customers. They also focus on improving production every day. This means lower costs and better quality.
Wiring harnesses are often designed and built according to the geometric and electrical requirements of the assembly. The diagrams are usually on paper or a computer monitor, and the wires are cut and respooled to the desired length. In addition, we may print or strip the wire to match the wiring harness design.
Cable Assemblies
A cable assembly consists of a series of cables that interconnect. Each cable is ideal for specific purposes. For example, a cable designed for a power supply must accommodate a particular current. In contrast, a cable used for a signal transmission must support the speed and size of the signal.
Cable assemblies are essentially two or more wires and cables that connect to the PCB. These cables can be of various shapes and sizes. Each cable assembly design depends on the operating environment. For example, a large-diameter cable will not work well for a high-frequency circuit, while a small-diameter cable will work better. The diameter of the cable also determines the voltage drop, which results from increased resistance in the circuit. Therefore, increasing the diameter of the cable can reduce the voltage drop.
A cable assembly is an essential part of an electronic device. The performance of an electronic device is directly related to the layout of the board and the type of cabling it uses. Printed circuit boards are essential in making electrical systems “talk” to one another. They are helpful in devices like cell towers, secure servers in military systems, and voice-over-Internet protocol devices.
We cannot advance PCBs if we don’t pair them with the perfect cable harness. Therefore, in the industrial world, custom wire and cable harness production and design is a key part of a company’s manufacturing process.
Wire Harness Design Factors
There are many important factors to consider when designing a single-wire harness. These factors can make the entire process more efficient and lead to better results. First, it is essential to determine the environment in which the wire harness will operate. We can expose the wiring in a vehicle to significant heat and humidity, dirt, oil, and chemicals.
Wires can have plating or bare copper and come in different gauges and insulation thicknesses. They can also have different connector plating or terminals. In addition, the connectors may require additional accessories, such as locks or labeling. Depending on the design, it may take several days or weeks to complete the entire wire harness.
In addition to determining the components needed for the wire harness, it’s also essential to consider the manufacturing constraints. These factors include cost, tooling requirements, and manufacturing time. It’s necessary to consider these factors to ensure maximum efficiency and safety. Wire harness design is an integral part of any electrical device.
When a wire harness is not insulated properly, it can cause issues. To prevent these problems, wires should be enclosed in a wire harness with a heat-shrink coating, reducing the risk of abrasion. These wiring harnesses are helpful in every industry, from automobiles to medicine to commercial construction. We can also find them in household appliances, home electronics, and audiovisual equipment.
Wire Harness Assembly geometric and electrical requirements
Wire harness assembly is a complex process that requires precise mechanical and electrical inputs. Therefore, assembly geometry plays a critical role in determining mechanical space requirements. The choice of connectors will also impact the amount of space available. In addition, wire bundles must have adequate length and diameter. We calculate the length of a wire bundle by considering the wire diameter and the length of wire paths.
After the electrical and geometric requirements are determined, the wire harness is fabricated and assembled. The wire harness assembly process begins with developing an assembly board, a full-size wire harness diagram. The board also serves as a workbench.
Wires and cables are measured and tested. In addition to testing for length and electrical requirements, manufacturers check the wire gauge and connectors for damage. They also look for proper spacing between wire terminals and pin placement. Digital systems can also be essential for recording any defects. After the wire harness assemblies are ready, they can be shipped or used as a component in a machine.
Wire Harness Assembly can be helpful in all sizes and scales of production. For example, a computer system could consist of tens of thousands of cables. These cables need to be routed and bundled for a reliable connection. The harnesses also speed up the installation of large systems. They also make it easier to identify the correct components. Wire harnesses also incorporate structural supports, insulation, and shielding to protect against dangerous short circuits.
The Differences
Despite the similarities in the manufacturing process, wire harnesses and cable assemblies are two different products. The differences between the two types of assemblies can lead to a lot of trouble when you are trying to source them from the same manufacturer. However, understanding these differences can guide your search for a reliable supplier.
Wire harnesses are cheaper
Outsourcing your wire harness assembly is an excellent option if your company currently completes the process manually or has limited equipment. With contract manufacturers, you can buy similar products in larger quantities and focus on improving your production daily. However, the downside of outsourcing wire harness assembly is that you may pay more for your wire harnesses.
Wire harnesses are usually less expensive than cable assemblies, but low cost electrical solution depends on the type of cable used and its quality. However, wiring harnesses can make your life easier because they are easier to thread through tight spaces. In addition, because they include smaller wires in a larger sheath, they’re easier to use and often have prefab parts for easier assembly.
They are lighter
A wire harness assembly consists of individual cables bundled into one large sheath. It consists of a thermoplastic or vinyl covering and offers added strength and endurance. It also includes many connectors and terminations. Wiring assembly can be difficult to route through small spaces, whereas cable assemblies are much easier to work with. They can also be more convenient because they often come with prefab parts.
Cable assemblies are best for connecting two PCBs. They can be bulky but are generally lightweight and easy to use. In addition, cable assemblies are faster to install than wire harnesses, which require a wire-by-wire installation.
They are more flexible
A wire harness assembly consists of several cables and wires. We cover these wires with an exterior sheath made from heavy-duty materials such as vinyl or shrink-wrapped thermoplastic. These materials resist abrasion and weather elements and protect the wires from friction, compression, and corrosion. Whether the wiring is for a home theater system or an industrial machine, a wire harness assembly will keep it in good shape and protected from damage.
A wire harness assembly is more flexible than a cable harness. It can include molded or sheathed connectors. It is generally helpful when connecting two PCBs. However, a wire harness is less bulky, more convenient, and easier to use. A wire harness also requires fewer steps in the assembly process.
They provide more protection from external factors
A wire harness assembly is an excellent way to protect the components of an electronic device from external factors. It protects against abrasion, moisture, and electrical shorts. It also helps prevent electrical fires and other electrical hazards. These harnesses are often customized and can incorporate features such as flame-retardant sleeving. They are helpful in electronic devices, medical diagnostic devices, machinery, and automotive vehicles
The wiring assembly in cable harness assemblies will have a protective sheath made from thermoplastic or thermoset materials. This provides essential protection against shock and corrosion, and the sheath ensures that the wires are insulated and have low resistance. You can also use gauges to test the resistance and capacity of multiple wires.
They consist of a protective sheath
Wire harness assemblies and cable assemblies consist of multiple cables or wires held together by a protective sheath. These covers consist of durable materials like vinyl, shrink-wrapped thermoplastics, or thermoplastic rubber. The protective sheath helps the cables or wires withstand harsh environments and provides additional protection. Wiring looms are also commonly used to combine multiple cables or wires in a single unit.
The wire used in wire harness assemblies is usually a single strand of copper or tin. A protective sheath protects individual wires from abrasion, moisture, or other damage. In some cases, cable assemblies are also essential to connect electronics.
Partec Cable and Wire Harness Capabilities
Partec offers a range of wire harness assembly services to meet various requirements. Wire harnesses are used to organize internal wires in electrical systems and can also reduce the amount of space needed to install wiring in tight spaces. In addition, its manufacturing and support capabilities allow Partec to build wire harnesses to suit any application.
Wire harnesses are an inexpensive electrical solution that organizes and protects groups of wires. They ensure that cables maintain the right length, orientation, and terminations and enable faster installation. Wire harnesses can consist of various materials, including sleeved wires, multi-conductor cables, ty wraps, and tubing. Most applications have their requirements for terminations and the wire harness layout.
Apart from standard wire harnesses, Partec also creates custom cable harnesses for various industries. This includes industrial wire harnesses, power supply harnesses, and electromechanical wire harnesses. The company can produce wire harnesses for all industries, from consumer electronics to medical devices.
