Cable harnesses are used in machineries that require multiple wires to be installed. Instead of having numerous wires installed for various applications, a cable harness groups them all into a single bundle covered with a sheath, and terminating with a type of connector specific to its function. Cable harnesses are used in a wide range of applications in a number of industries like automotive, aerospace, military, medical, and any other that would require machinery.
Whatever the type of industry or application, and whatever the type of harness (double-wired or multi-wired), the assembling process of a cable harness is generally the same for all. The basic steps for assembling a cable harness include –
Wire cutting – Wires within a single harness must have same lengths, and the length must be of a precise length as suitable for the design. Thus, wire cutting is the first and foremost, and the most critical step of a cable harness assembling procedure. For this, assemblers measure and mark the wires first, and then cut them.
Wire bundling – The wires when cut of the same length are then laid out as directed in the cable harness design. Once organized properly, they are then held in position with a tape or cable tie.
Wire termination – Every wire within a harness is required to be terminated. Each wire is connected to a connector by stripping the insulation away, crimping contacts onto the end of the wires, and inserting the wire into the connector.
Harness testing – Once the harness is constructed, it is critical for it to be checked and tested. This involves everything from visual inspection to an array of assessments using digital testing tools. There are also other cable harness manufacturers in India who perform quality control checks on the procedures at each step of the manufacturing process.
Final finishing – Once the harness is manufactured and tested, and if everything seems fine, it is then finished as required by the application or client. It could be applying protective caps on the connectors, shrink tubing, or anything else.
You can opt for standard cable harnesses made out of general materials into a general design. Or, you could also opt for special customized services, where you can use the materials you prefer, and choose any of the actions you wish your cable harnesses to undergo – stripping, twisting, dyeing, labeling, heat shrink tubing, any anything else. This kind of customized cable harness results in better quality and a product that fits exactly into what you want just the way you want it to. This is because the entire process is paid personalized attention to.
Miracle Electronics is one of the most reliable cable harness manufacturers in India where you can get both standard as well as customized harnesses. Whatever you choose, you can rest assured to get the best quality products as we pay attention to every process, whether it is a standard procedure or a personalized one. This can be proven with the certifications for quality we have received for our production processes – ISO 9001 and AS9100C. Moreover, our cable harnesses are all certified and approved by DGAQA and MSQAA for platform specific applications.