A wire harness, also called as cable harness, cable assembly, wire loom, or wiring assembly, is a group of wires clubbed together into one unit to transmit signals and provide electrical power to various applications. These harnesses consist of multiple components along with the many wires they constitute of. The wires clubbed together could be of any type ranging in hook-up wires, multi-pair cables, multi-conductor cables, and coaxes. There could be a combination of any of these wires, depending upon the design of the harness. These equipment are designed according to the geometric and electrical requirements of the equipment they will be installed in. Miracle Electronics is a leading wire harness manufacturer in India who undertakes requests for custom design and development of wire harnesses. This is where you can get all your required wire harnesses that are certified for quality to ISO 9001, AS9100C; and are approved by DGAQA and MSQAA for platform specific applications.
Which applications require wire harnesses?
Wire harnesses are used in a wide variety of applications, with the automobile industry being one of the largest users. The automobiles could be two wheelers, three wheelers, cars, buses, trucks, planes, utility vehicles, or commercial vehicles. Other applications include industrial equipment, construction machinery, white goods, data communications related equipment, and electro-mechanical components, to name a few.
Why are wire harnesses better than loose wires?
Wires add up to miles of length, thus multiple wires means requirement of quite some space. On the other hand, a cable harness reduces the space needed by neatly combining the wires into a single unit. Moreover, installing multiple wires needs more installation time, which is not the case with a cable assembly. Another major benefit that cable harnesses provide is the reduced risk of adverse effects caused when wires come in contact with moisture, vibrations, and abrasion. The protective flame retardant sleeves covering the wires also lower the risk of electrical fires and shorts during repairs. Therefore, wire harnesses optimize space, reduce installation time, and are more secure than bundles of wires.
How are wire harnesses constructed?
First, the design is planned with a full size diagram depicted complete details about the assembly preparation and operation. Based on this diagram, the wires are cut to desired lengths with the help of wire cutting machines. The wire ends are then stripped off of insulation, and then labeled and marked for identification in the further stages. These wires can then be attached to any required terminal or connector, which is done through specialized automated equipment. The terminated wires are then routed, assembled and clamped together on the assembly board. The harness is fitted with protective sleeves, tires, lacing, or conduit. The last step of the production process is testing the cable harness for electrical functionality.
How far can wire harness production be automated?
In spite of the increasing automation we see around in every industry, wire harnesses are mainly manufactured by hand because of the various processes involved like installing varying lengths of wires, running wires through sleeves, taping the wire harness where there are branch-outs, conducting crimps on specified wires, and binding various components together. Due to these diverse processes, manual production remains more cost-effective as compared to automation in the case of cable harnesses.
However, certain processes can be automated. These include cutting and stripping off the ends of wires, crimping the terminals, plugging wires into connector housings, and soldering or tinning of wire ends. Also, one important process where automation can prove to be useful is the testing phase. Here, a test board is designed that will have mating connections for every terminal of the harness. The harness is plugged into the test board to electrically check it for any faults.