In the past, not much importance was given to cable harnesses, which is why they were the last components to be designed in an electronic system. This created problems of not leaving room for the interface, or for not being able to design harnesses that could meet the expectations. With these problems being encountered, there came the realization of a cable harness being a system’s true lifeline.
A cable harness is what determines a major portion of the overall performance of the entire system. Any failure in the harness means failure of the entire system. With this realization, much importance is being given to these harnesses today. And, with such importance, grow their complex designs. In fact, today, various electronic components like switches, LED, and PCB are being integrated directly into the finished design of the cable harness. This is because cable harness manufacturers in India have realized that the addition of these components offers cable harnesses a much higher level and capability of withstanding rugged working environments. Moreover, the termination points can be controlled better, and the electronic components can be protected against environmental stresses; thus improving the overall performance of the system. And, with the electronic components being protected, the connections are also protected, bringing in lesser chances of problems and failures.
There are various ways in which electronics can be protected within a cable harness. These include incorporating an overmould into the design, and also including a strain relief into the overmould. Incorporating an overmould will provide a dust-free, fluid-free, and tamper-proof seal to the electronics, terminal points, and junction of the cable shields with the connector body. The strain relief included can eliminate any stress points at the termination area. With such isolation of the components from the outside world, along with isolation inside the overmould cavity, any possibility of wear damage is completely eliminated.
How and to what extent can electronic components be included with cable harnesses varies with the situation and requirement. For example, RFID tags and locking software can be put on paddle cards that are terminated to the connectors; or battery charging electronics and fuel gauges can be built into overmould and LEDs; and switches can be included in the overmould or attached to the end of the cable. Whatever option is chosen, but it is a fact that including electronic components within cable harnesses can boost up reliability by allowing the components to be completely protected from almost any kind of environment. Thus, you can save space on the equipment, while also keeping the electronics sealed and protected with cable harnesses that have electronic components integrated in their design.
Cable harnesses are used in almost every environment – industrial, medical, aerospace, and aquatic – each creating a different situation that the harnesses need to withstand. And, to design harnesses that can withstand the particular challenges, it is important to first understand the installation environment of the harness and any electronic components included in it. Miracle Electronics are expert cable harness manufacturers in India who can design any kind of customized cable harnesses for your application, may it be automotive, aerospace, military, medical, industrial, or any other.