Understanding the Different Types of Cable Harnesses

Reliable electrical systems are more critical than ever. From powering automated machinery to managing HVAC systems and keeping telecommunications networks running smoothly, the role of organized and durable wiring cannot be overstated. That&#;s where cable harnesses come in.  

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Cable harnesses are the unsung heroes that keep these systems functioning efficiently and safely. In this guide, we&#;ll break down the different types of cable harnesses, explore what makes each unique, and show how they&#;re used across various Canadian industries. Let&#;s dive in.  

What is a Cable Harness?  

First, let&#;s cover the basics: what exactly is a cable harness? Simply put, a cable harness is a collection of wires, cables, or subassemblies bundled together with materials like plastic, nylon, or braided shielding. These bundles organize and protect wiring, simplifying installation and ensuring everything stays durable and secure.  

Here&#;s why cable harnesses matter:  

• Protection: They shield wires from wear and tear, environmental damage, and accidents.  
• Efficiency: Bundling wires together makes installation faster and less complex.  
• Safety: A well-organized system reduces the risk of electrical shorts and fires.  
• Durability: Cable harnesses are built to withstand harsh conditions, keeping systems reliable.  

Whether you&#;re working with automated machinery, HVAC systems, or telecommunications equipment, cable harnesses are essential for keeping everything running smoothly and safely.  

The Most Common Types of Cable Harnesses  

Not all cable harnesses are the same. They come in a variety of materials and designs, each built for specific needs. Here&#;s a look at some of the most popular types.  

PVC Cable Harnesses

PVC harnesses are versatile, weather-resistant, and flexible&#;making them a go-to choice for many industries. They&#;re particularly great for environments where equipment faces fluctuating temperatures.  

• Key Features: Durable, cost-effective, and resistant to weather changes.  
• Common Uses: Automated machinery, HVAC systems, and commercial equipment.  

Nylon Cable Harnesses

Nylon harnesses stand out for their abrasion resistance and ability to handle high temperatures. This makes them perfect for heavy-use environments where reliability under stress is a must.  

• Key Features: Tough, lightweight, and heat-resistant.  
• Common Uses: HVAC systems, manufacturing equipment, and other demanding industrial setups.  

Braided Cable Harnesses

These harnesses have a braided design that protects against electromagnetic interference (EMI) and adds extra physical durability. They&#;re ideal when signal quality is non-negotiable.  

• Key Features: Excellent EMI shielding and robust construction.  
• Common Uses: Telecommunications, medical devices, and data systems.  

Ribbon Cable Harnesses

With their flat and organized layout, ribbon harnesses are perfect for setups where space is tight. They&#;re especially popular in electronics and compact industrial systems.  

• Key Features: Space-saving and easy to integrate.  
• Common Uses: Compact automated systems, electronics, and small machinery.  

Fibre Optic Cable Harnesses

Fibre optic harnesses are all about speed and reliability. They&#;re designed for high-speed data transmission, ensuring minimal signal loss and high bandwidth&#;critical for modern communication systems.  

• Key Features: High-speed data handling and exceptional signal integrity.  
• Common Uses: Data centres, telecommunications networks, and advanced systems.  

How Canadian Industries Use Cable Harnesses  

Cable harnesses play a significant role in many industries across Canada. Here&#;s a closer look at how they&#;re used and why they&#;re so valuable.  

Automated Machinery

Cable harnesses help manage complex wiring for production lines and industrial equipment while keeping systems efficient and reliable. PVC and braided harnesses are especially popular in this space.  

Why They&#;re Essential: Reduced maintenance, streamlined operations, and fewer wiring issues.  

HVAC Systems

In HVAC equipment, wiring needs to handle temperature shifts and demanding conditions. Nylon and PVC harnesses provide the durability and flexibility these systems need.  

Why They&#;re Essential: Reliable performance and extended system lifespan.  

Telecommunications

Telecom networks rely on fibre optic and braided harnesses to keep data flowing smoothly and without interference. These harnesses are key to maintaining clear and reliable communication.  

Why They&#;re Essential: Consistent signal quality and interference-free operation.  

Commercial Equipment

Commercial equipment needs efficient wiring solutions, from supermarket conveyor belts to storage systems. PVC and ribbon harnesses are excellent choices for these applications.  

Why They&#;re Essential: Easy integration, space efficiency, and durability.  

Why Choosing the Right Cable Harness Matters  

Picking the right cable harness isn&#;t just about ticking a box&#;it&#;s about improving your systems and saving time and money in the long run. Here&#;s how the right harness can make a difference:  

• Improved Efficiency: Simplifies installation and boosts overall system performance.  
• Enhanced Reliability: Keeps systems running smoothly under harsh conditions.  
• Greater Safety: Reduces the risks of electrical hazards.  
• Cost Savings: Durable designs mean fewer repairs and replacements.  
• Longer Lifespan: Protects your investment by ensuring your systems last longer.  

How Tevelec Delivers Tailored Cable Harness Solutions  

When it comes to cable harnesses, one size doesn&#;t fit all. That&#;s where Tevelec steps in. With years of experience and a commitment to quality, Tevelec provides custom solutions designed to meet the specific needs of Canadian industries.  

Here&#;s what you can expect:  

• Tailored Solutions: Cable harnesses customized for your specific application.  
• Top-Quality Materials: Built for performance, safety, and reliability.  
• Compliance with Standards: Designed to meet Canadian industry regulations.  

Whether you need a harness to support automated machinery, HVAC systems, or telecommunications equipment, Tevelec has the expertise to deliver.  

Ready to Find the Right Cable Harness for Your Needs?  

Cable harnesses are the backbone of modern electrical systems, helping industries run more efficiently, safely, and cost-effectively. Choosing the right harness for your application can significantly improve performance and reliability.  

Tevelec is here to help. With customized solutions and a focus on quality, we&#;re ready to provide the perfect cable harness for your business. Get in touch today to learn more about how we can support your needs!  

Tevelec is a leading wire and cable manufacturer and distributor in Canada, offering a diverse range of high-quality, tailored wire products designed to meet the unique needs of various industries. As a customer-centric company, Tevelec is committed to quality, sustainability, and expert guidance.

Discover the comprehensive range of high-quality wires and cables, including mini-split cables, fire alarm cables, and more, tailored to specific industry requirements.

Wiring harnesses a compelling piece to combine several wires and conductors in order. Without proper wire insulation, the connection of different cables and strands within the wire harness can be damaged. You get to choose from other materials for wire insulation, and the selection of the material depends upon the work environment and layout of the wire harness.

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Copper-cored wire wrapped in plastic

CLOOM Tech offers five different types of wire insulations for custom wiring harnesses for industrial and commercial projects. Here is a brief introduction of every wire insulation type the technical specifications of the materials.

1. Polyvinyl Chloride

PVC has a wide range of electric cable manufacturing applications as bedding, insulation, and sheathing material. PVC was an advanced and better alternative to rubber insulated wires as PVC was more accessible to process than rubber sheathing. As you will not replace or repair custom wiring harnesses any sooner; hence, PVC offers an excellent lifespan. The cost of PVC is less than many other wire insulation materials.

PVC is one of the most flexible and versatile thermoplastics due to its fantastic flexibility. The original properties of PVC make it rigid and challenging, but it is useable in different applications after easy modifications. The processing of PVC is easy, and it is also recyclable. During the selection of material for wire insulation, fire resistance is an important consideration. Most industrial applications require such fabric for wire insulation and cable sheathing that can withstand higher temperatures. The use of PVC for wire insulation in wiring harnesses allows the harnesses to perform effectively despite the temperature rise.

Wire insulation for different applications

Apart from high-temperature resistance, PVC insulation can protect wires against oils and chemicals too. The chemical exposure is too regular in many industrial work settings, so you can opt for PVC insulation if there are any chemical exposure chances.

Examples of PVC Applications

In many wires and cables, you will find PVC as the primary insulation material. CLOOM Tech also offers modified PVC insulation for custom wiring harnesses according to the requirements of the client. Here are some significant examples of PVC insulated wires:

• As jacketing and insulation for low voltage wires
• Cable jacketing for medium and low voltage appliances
• For local telecommunication cables
•  In wiring harnesses for automotive.
• Flexible wires for better protection against tearing

2. Fluorinated Ethylene-Propylene

FEP is the blend of hexafluoropropylene and tetrafluoroethylene. FEP materials are modifiable after melting. This material is a perfect insulation material for temperature sensing wires, but its use for wiring harnesses also has some benefits. FEP has countless applications in industrial units as insulation and jacketing material for wires and cables. In coaxial cables, this material can perform as a dielectric too. The outstanding resistive properties of chemicals make it a suitable option for wire insulation in wiring harnesses.

Insulation of wire in different colors for several applications

When it comes to temperature resistance, FEP offers great resistance temperature ranges. Due to its excellent electric and physical properties, manufacturers use FEP in many industries and projects. In TEC cables, manufacturers use FEP as filler material. These TEC cables are perfect for the gas and oil industries. FEP is an excellent option for wiring harnesses for military installations and applications. FEP has countless applications in commercial and industrial projects due to its ideal temperature and chemical resistance properties.

Whenever you need wiring harnesses with flexible yet rigid insulation material, you can choose FEP as protective material. FEP can withstand all weather conditions with effective water resistance properties if you are concerned about changing weather conditions.

Applications of FEP Insulation

Almost every industry has some space for FEP as insulation for custom wiring harnesses. Typical industrial applications of FEP as wire insulation include:

• Military installation and military-grade equipment
• Oil and gas units where chemical exposure is a common problem
• Chemical industries with harsh work settings
• Medical facilitates that need sterilization of wires and wiring harnesses.
• Aviation and aerospace sector
• Cars and vehicle manufacturing units

3. Polyethene

Polyethene insulated wires are best for projects where high voltage is involved. From electrical properties to resistance against different levels of temperature, Polyethylene is suitable for harsh conditions. In various applications where general sheathing materials would fail, manufacturers use Polyethylene as an insulation material. From freezing conditions to boiling applications, Polyethylene can withstand both extremes.

The wiring harnesses with a coating of Polyethylene are rigid but offer better resistance against abrasion. The original chemical properties of Polyethylene make it a tough and solid material. In the original form, Polyethylene may not be suitable for wires where you need flexibility. But with some further modifications of additives and fillers, you can make it flexible according to the project specifications.

Close up of electric cables with insulation

Polyethene insulation is the perfect choice to minimize power loss. The leakage of current or data from wires with Polyethylene coating is almost negligible. You will get a maximum efficient current supply with Polyethylene insulated wires from low or high voltage current-carrying wires. What makes Polyethylene a better choice as compared to other insulation materials?

Polyethylene&#;s additional properties make it a suitable coating material for high-frequency signally carrying wires and transmission lines. For all the appliances that involve audio data and radio frequencies, custom wiring harnesses with Polyethylene coating can perform better than other typical coating materials.

Different Types of Polyethylene

There are different types of PE, depending upon the chemical properties of the material. Polyethene is originally lightweight, chemically inert, and water-resistant. Here are different types of PE:

• Low-density PE
• Linear low-density PE
• Medium-density PE
• High-density PE
• Chlorinated PE
• Cross linkable PE

4. Nylon

Thermoplastic materials for the insulation of wires in custom wiring harnesses are less expensive as compared to thermosets. There are realities of wires and cables that feature different insulating materials according to the project specifications. Each material has some benefits over others, as some are soft, and some exhibit rigid attributes.

When it comes to soft materials for wires in custom wiring harnesses, manufacturers look forward to PVC or Nylon. Both are highly flexible and adjustable according to the project specifications and harness layout. In some industries like automotive and aerospace industries, Nylon seems to be a perfect choice. Although this material is flexible, Nylon&#;s toughness can protect the wires against external factors and abuse. When many bending and mechanical movements are involved, custom wiring harnesses with Nylon insulation can perform better. The strain relief and flexibility of Nylon insulation are way better than many other insulation materials.

Macro detail of some cables

Benefits of Nylon for Wire Insulation in Wire Harnesses

Apart from Nylon&#;s easy availability as insulation material, the price of Nylon is also less than other materials. Many clients prefer to have custom wire harnesses with Nylon insulation due to their low cost and functional properties. The following are some unique advantages of Nylon.

• Nylon is a highly flexible and soft material that is perfect for insulation.
• The rigidness of Nylon makes it tough insulation in the original form.
• It has a string of abrasion resistance properties.
• Nylon provides better protection against tearing and cut through.
• The chemical resistance of Nylon makes it excellent insulation for industrial projects too.

5. Thermoplastic Rubber

Thermoplastic rubber is the primary focus of custom wiring harnesses manufacturers. The fantastic properties of Thermoplastic Rubber make it a better option for the insulation of wires with a minor investment. The processing of Thermoplastic Rubber does not require a lot of processing, making it an affordable industrial application option.

Electrical tester wires tying cables bolt cutter pliers

The use of Thermoplastic Rubber for cable insulation and jacketing is nothing new as this material has been around for a long time. The unique physical properties and low processing costs make it a desirable material for custom wiring harness manufacturers. It is the most flexible material out there if we compare Thermoplastic Rubber with other thermoplastic insulation materials. Even after stretching the material to a sufficient elongation, Thermoplastic Rubber will return to the original shape. Hence, improved flexibility leads to the enhanced lifespan of the wires and cables.

Properties of Thermoplastic Rubber

Here are some unique physical and chemical properties of Thermoplastic Rubber that make it a perfect choice of wire insulation in custom wiring harnesses:

• Higher processing speed leads to faster production.
• Temperature resistance against extreme temperature levels
• Excellent resistance against weather and heat ranges
• Enhanced lifespan with the better ageing process

Conclusion

CLOOM Tech can manufacture custom harnesses with any insulation material regardless of your project specifications and work environment requirements. You can contact us for bulk production of custom wiring harnesses with different protective coatings and insulations.

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