Wire Harness or Cable Assembly – Which Do YOU Need?
Wire harnesses and cable assemblies, each used to transmit signals or electrical power between the different electrical devices. These two terms are often used interchangeably, and the products themselves have very similar functions. Hence, referring to a wire harness as a cable assembly, and vice versa, however, they are very different in complexity and applications.
Before we dive into the discussion on the differences between the wire harness and cable assembly, it may be helpful to distinguish what a cable is and what a wire is, given that terms are also used interchangeably despite being very different products. While these two products have very similar functions, there are also differences as well. Both wire and cable are designed to carry electricity from one end to the other. Essentially, a wire is a single metallic strand that conducts electricity from one point to another, while a cable, by contrast, is a bundle of two or more individually insulated wires that are either bonded or braided together in a protective sheath.
Wire harnesses and cable assemblies both serve a similar purpose, bundling several wires or cables together to keep them organized. The main difference between a cable assembly and a wire harness is that a cable assembly creates a path from one point to another, while a wire harness usually contains multiple ends or branches, running in different directions, with multiple terminals on each branch.
Understanding a Wire Harness
A wire harness is a low-cost electrical solution to neatly arrange an electrical wiring system. It bundles up several point-to-point insulated wires and wraps them together into one conclusive, highly organized assembly. Wrapping bands, cable ties, or some type of protective sleeving made of a material such as thermoplastic are commonly used to protect wires from environmental conditions such as moisture, heat, or friction, to bundle wires together as a unit, and to arrange the different breakouts for easy routing through a system or box build.
The primary purpose of a wire harness is to group different wires that are already protected by an outer layer for better connectivity. They help keep the electrical system in order by preventing unnecessary interaction of individual cables or circuit couplings. Wire harnesses ensure the maximum utilization of space in small areas and wire is not run all over the place.
A wire harness has a limited load capacity depending on the number and sizes of bundled wires. It is good to use indoors where the wire will not be exposed to environmental threats such as extreme heat, moisture, dust, or friction. A wire harness is used in durable goods like household appliances, in and around engines of all kinds – automobiles, buses, ships, trucks, and even planes. Electronic equipment, machinery, electrical panels, industrial equipment, all use wire harnesses.
Advantages of a Wire Harness
- A low-cost option for organizing multiple cables
- Convenient to modify the component cable as needed
- Suitable for indoor applications
Understanding a Cable Assembly
Cable assemblies come in many shapes and sizes. It is a group of wires or cables that have been bound together in a single strand with a connector or plug on each end, keeping the wire and cables organized. Most of the time, they are covered by an external sleeve made from a variety of heavy-duty materials like vinyl, thermoplastic rubber, or shrink-wrapped thermoplastic. Generally, a cable assembly is designed to perform specific functions as determined by the plugs, terminals, and connectors that are found on each end. It is ideal for routing groups of wires and cables around obstacles. Cable assemblies are used in a variety of industries such as military, aerospace, telecommunication, food, robotics, oil and gas, electronics, manufacturing, healthcare, and many others.
Because of their robust design, cable assemblies are most suited for outdoor applications and high current applications. The cable assemblies are able to withstand heat, friction, moisture, abrasion, dust, hazard, and other environmental conditions due to the durable structure of the sleeve that encases them. Cable assemblies may be the more expensive option as compared to the wire harnesses, but they will keep the product protected in the most extreme conditions.
Since the wires in each cable assembly are bound into a comfortable sheathing or jacket, each piece of the cable assembly is easier to organize and route into a different location. Furthermore, cable assemblies can be designed to meet the specific demands of a particular environment and color-coding makes it easier for the electrician during installation and maintenance.
Advantages of Cable Assemblies
- Convenient and flexible routing design
- Since the bundled smaller wires are in a large sheath, they are easier to thread
- Designed for outdoor applications
- Can handle larger electrical loads
- Durable enough to withstand harsh environmental conditions
Contact Exxel Technology for Your Cabling Solution Needs
The confusion about wire harness and cable assembly as cable solutions is understandable since both terms are often used interchangeably. However, both products are very different from one another, from their physical features, purpose, impact on the industry, and individual share of advantages.
Cable assemblies and wire harnesses are essential components for all types of networking, connectivity, communication, equipment, and a variety of other applications. Whether you need a custom cable assembly or a wire harness for a job will depend on the specific application. With an understanding of the different applications between the two, you can easily choose the right cabling solution to fulfill the job requirements.
Exxel Technology Pte Ltd specializes in the engineering and fabrication of custom cable assemblies and wire harnesses. We are more than just a wire harness and cable assembly company. We also provide a complete contract manufacturing solution.
Contact the Exxel Technology team today to learn more about our services or to request a no-obligation discussion.
