Wire Harness – The Technicalities

Cable and Wire Harness - Connector - Exxel Technology Pte Ltd

What is Wire Harness

Wire harness, also often known by the terms wiring assembly, cable harness or cable assembly, is basically a fabrication of cables or wires that channelize signals or electricity. The cables are restrained together either solely or with a combination of , connectors, straps, cable ties or lacing, sleeves, electrical tapes, conduit and an extruded string. It is commonly used in many industries, such as automobiles, marine, aerospace, control panels, machinery and etc.

Wire Harness Application

The use of wire harness is comes with many advantages over loose wires. As the cables are bound into a single, non flexible harness, it optimizes the use of space, reduces the risk of shock and helps to standardize the production process. A single cable harness as opposed to numerous wires is considerably easy to install and is therefore time efficient. Also, fastening of many wires and cables into a harness makes them safer against the damaging effects of vibrations, chaffing and moisture. If the wires have been bound into a flame retardant sleeve, it cuts down the risk of electrical fires.

Wire Harness Production Process & Quality Check

The process of wire harness production is very detailed. The diagram of the wire harness is first drawn according to electrical and geometric requirements and then the same is provided on paper or monitor for assembly preparation and final assembly. The wires are cut and the ends are stripped to expose the core to the exact length specified in the drawing. The ends are then crimped with required terminals or connector housings using specific tooling or solder to the terminals to ensure proper connection. The wires are then assembled on a special workbench or an assembly board following the specification provided. It is either fitted directly in the equipment or shipped, after the harness has been secured with protective sleeves or other such measures.

Though the practice of automating the production process is on the rise, most wire harness continues to be manufactured by hand. The steps of securing the wires with protective taping and sleeves, fastening of clamps and others are difficult to achieve through automation especially for the case of low volume high mix wire harness production.

Before shipment, the wire harness is checked for electrical functionality though a series of test, including visual inspect to ensure the wire harness is assemble and conform to various dimension given, connectivity test, short circuit test, pull test and etc.

Contact us at sales@exxeltech.com for a non-obligated discussion to fulfill your specific manufacturing needs.



Switch to desktop version