Wire harnesses is nothing but connecting two devices through wires or cables. It may a single wire or bundles of wires bound together. Due to its complex nature, letâ&#;&#;s explore the elaborate details of wire harnesses, their application, and their manufacturing process.  

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What are wire harnesses?  

Wire harnesses are typically a bundle of wires bound together by additional covering that helps guard against environmental conditions and other potentially harmful factors. The extra shell prevents the wire from wear and tear due to previously mentioned factors. These harnesses are essential because they are organized, so installing them into equipment becomes relatively more straightforward. Wire harnesses often get mistaken for cable harnesses or cable assemblies. Wire harnesses mainly provide easy organization of wires while installing equipment and only offer a certain degree of protection. In contrast, the cable assemblies bind multiple wires tightly to provide sturdy support against the environmental conditions in the picture.   

Wire harnesses provide numerous amounts of benefits, and they are:  

• Helps with wire management within the machinery setup   
• It gives a scope of optimization for specific situational needs  
• Increases the lifespan of wires and cables  
• Increases the safety of the equipment  
• They are available in a versatile range of lengths and sizes  

Few applications of Wire Harness  

Wire harnesses have a range of applications. Here is an elaborate list of several names of equipment and device that uses wire harness:  

• Locomotives: Wires harnesses are used in vehicles to relay information such as direction indication, electrical power, etc  
• In aerospace: Wire harnesses are used in flight simulators to transmit information while compliant with various performance standards and precise spacing requirements. This is done because aeronautical objects move with immense velocity, so to avoid any mishap with the wires, wires harnesses are used as they would provide some resistance to the atmospheric pressure and impact of air due to the velocity of the flying object.   
• The panel displays for flat screens: Flat screens use wire harnesses as there is already less volume in the body to fit all the critical components necessary for the screen to work.    
• Rugged computer- These computers are used in harsh environments like industries with heavy workloads and warzones. Hence wire harnesses are installed in the system as they are protected from dirt, dust, fungus, etc., due to the additional coverage that bounds them.   

Apart from the sectors mentioned above, Wire Harnesses are also used in machinery involved in industrial equipment, construction appliances, home appliances, military and defense systems, medical equipment, and many more. 

What is the manufacturing process of wire harnesses?  

The manufacturing process of wire harnesses is partly complex: 

The process always starts with its designing phase. Wires harnesses are used in industrial machinery, washing machine, etc. Hence its design also varies depending on its purpose and workload. Therefore, creating a customized wires harness is one of the challenging aspects of its manufacturing process. The engineers must consider the possible issues wire harnesses may face in particular machinery while designing them.    

Then a prototype is created to determine how the wire harness will work. The manufacturing process of wire harnesses is primarily manual. Manually assembled parts help resolve electric and space issues with certain complex products. The next step is called wire cutting. The wires are cut according to the machine requirement where the wire harness will be used. In the end, safety testing is run as it should for any electric component. In this last phase, utility and sustainability are checked rigorously.   

As one of the leading wire harness manufacturers in India, Elcom International offers a range of highly efficient wire harness solutions. ELCOM International, as one of the prominent harness manufacturers in India, specializes in creating electromechanical and electronic components with the mindset of producing world-class products. Backed by extensive research and advanced technology, Elcom International, a reliable wiring harness manufacturer, assures quality by complying with industry standards and manufacturing practices. Leveraging years of experience and expertise in the domain, Elcom International, one of the best wiring harness manufacturers in India, wins over competitors by incorporating top-notch practices and customer-centric solutions.  

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The Wire Harness Manufacturing Process

Wire harnesses are bundles of electrical wires that each have their own individual covering but are also bound together using an additional outer covering. The term wire harness is sometimes used interchangeably with cable harness or cable assembly, though there are subtle differences between them. In this blog, we will discuss everything you need to know about wire harnesses, including what they are, how they are used, and how they are manufactured.

What are Wire Harnesses?

Wire harnesses are bundled processed wires with a protective covering to guard against wear and tear due to environmental conditions and other potential damaging factors. They may have a protective sheath around the wires that is typically made of thermoset or thermoplastic material, which provides additional protection against damage to the individual wires. These harnesses are important because they organize wires for easy implementation into equipment and systems.

Wire harnesses oftentimes get confused for cable assemblies. Wire harnesses typically provide a bunch of cables and wires with some degree of protection and keep them organized, while cable assemblies bind multiple covered wires tightly with a covering to provide robust protection suitable for more demanding environments. Despite the product names, both cables and wires may be found within wire harnesses and cable assemblies.

Wire harnesses offer a range of benefits, such as:

• Optimizing space by grouping wires together
• Facilitating customization for specific application needs
• Providing extended service life on cables and wires
• Improving equipment safety
• Availability in a broad range of sizes and lengths

What are Wire Harnesses Used For?

Wire harnesses are used in far too many applications to list here, but here are some specific examples of notable use cases for wire harnesses:

• Automotive. Wire harnesses are used in vehicles for a variety of purposes, such as relaying information, signals, and electrical power.
• Flight simulators. Flight simulators use wire harnesses to transmit energy and information in accordance with various performance standards and tight spacing requirements.
• Flat panel displays. Flat screens incorporate wire harnesses to keep wires organized and to mitigate electromagnetic interference.
• Heavy equipment. Wire harnesses are incorporated into most heavy equipment used in construction and a variety of industries.
• Ruggedized computers. Ruggedized computers used in harsh industrial or military environments often incorporate wire harnesses and cable assemblies to protect internal wires from dirt, dust, moisture, and other elements.

These examples only make up a tiny fraction of relevant use cases for wire harnesses, which see extremely broad usage across major industries such as appliances, construction, heavy and industrial equipment, electronics, military and defense, medical equipment, and many others.

How is a Wire Harnesses Manufactured?

The manufacturing process for wire harnesses can go from basic to very complex. It starts with the design process and making sure that the harness incorporates any necessary custom features for its intended application.

The next step usually involves wire cutting, stripping, and terminating. The wires are stripped and cut at the right length and metal terminals are attached to the ends of the wires all using a specialized machine commonly known as a crimp center. If needed, the wires will then be inserted into a connector housing, allowing the mating of male and female bundles of wires.  Some wires will remain outside of connectors and attached to the original equipment individually. Finally, the cables or wires are bound with an outer covering using an assembly board, which guides proper breakouts and allows for final electrical testing.

Manual assembly is still the most common method for wire harness manufacturing because routing cables or wires through sleeves is an extremely delicate process. Manual operations for wire harness assembly include:

• Applying fabric tape in varying locations and amounts
• Crimping terminals onto wires, which sometimes requires multiple crimping operations
• Inserting one sleeve into another
• Fastening strands of clamps, cable ties, or tape

Wire Harness Manufacturing by PMCI

At Precision Manufacturing Company, Inc. (PMCI), we work with clients from wire harness design and schematic development into prototyping and production. Our wire harnesses are offered as a turnkey solution, which includes every process from conception through installation. We submit every wire harness to electrical safety testing to ensure it is safe for use.

Our wire harness assembly services include:

• Multiple wire and cable integrations
• Custom configuration
• Quick installation
• 100% fit, form, and function validation
• In-line wire and cable marking
• Harness sub-assembly prefabrication
• Ultrasonic welding for in-line wire splicing

Please contact us or request a quote for more information about our wire harness options and capabilities.

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