Defining Wire Harness

To say that cables are to the electric power generation and distribution industry what blood is to man, will be stating the obvious, in very clear and succinct terms. The reliance of electricity on cables as a form of transport is massive. Achieving this aim effectively through conducting electricity from the point of generation to the end consumer in a cost-effective manner using the most astute of materials – is a subject on which research and development may never cease.

Where is a wire harness needed?

Automobile wire harnessWithin the closed system of machinery and equipment, for example, an automobile, there is always need to transmit electric power and signals from one point or the other. This is where cable harnesses are thus needed.

These are packs of wires or cables collected together by way of a bundle, for specific applications. The cables are bound together in their numbers by cable straps or ties, cable lacing, sleeves, tapes of electrical conduit.

The material that binds them together constitutes the stringed combination, which organizes the assembly of cables and wires and makes their focus single in transmitting the signals from one point to another.

Functional application in machinery and automotive

There are a number of reasons a defined circuit finds better application in such a system, as regards complex machinery with different organs that must have some charge of an electric signal or the other to function as a unit. Whereas some wires can be used in a scattered manner to join two points together, providing a potential difference necessary for current and signal flow, this piece provides the advantage of economy of space.

By binding the wires together with a suitable material such as electrical weave of extruded string, a lot of precious space is saved up in the device. This does not only save space but makes for a more organized and aesthetic outlook of the interior of the machine. It makes the job of the Maintenance Engineer or Technician simple and straight to the point since he just has to look for an assembly of wires performing a specific purpose and do the needful.

The benefits of a wiring harness

Secure wires from abrasion and moisture

Cable assembly also help the wires by securing them from the unhealthy effects of abrasion and moisture. A mental picture of a mass of scattered wires stretching for tens of kilometers around the working part, as against a combined collection of wires converged to a point by a strap, would tell the obvious story. Service vibrations during the operation of the device are expected, and there is no better way of securing these wires from the effects of vibration than binding them with suitable material.

Prevention of short-circuits

Prevention of short-circuiting has also been known to be a fringe benefit of cables since there is every chance of vulnerability of a mass of scattered wires to the agents of short-circuiting. The installer has less work to do since he has only one group to install, as opposed to a mass of cables or wires. In addition, the process can be standardized, and a notation inculcated since it is a question of just one section, which may not be possible with a conglomeration of wires and or cables. To greatly reduce the probability of sparks and resulting fires, the item can be bound into a fire-retarding sleeve.

The different types of wire straps

There are different types of the assemblies, depending mostly on the device and application on which it is used. They include the standard wiring, reverse wiring, stereo relocation, amplifier integration, amplifier bypass, premium, and speaker adapter harness.

In the mainstream production of a painless wiring cords and cable harness assembly, several key factors must not be toyed with. These are considerations which must be attended to, and they include:

  1. For a custom process, the peculiarities of the machine and device on which the group will work are absolutely necessary.
  2. The cut and stripping requirements of the equipment kit ought to be determined and known.
  3. Methods of testing the quality of the electrical items produced have to be standardized and reliable.

The main details of producing these products are as follows:

Step one

First, a circuit diagram is produced showing the various parts of the device requiring transport of electric signal, ready for the preparation and assembly. The wires are then cut to size using a special machine. After this is done, the wires are stripped to expose the core of the wire, usually metallic in nature. These will be fitted into the connector housings, also known as crimping.

Step two

Clamping of the wires is the next thing to be done, and this is done on a special workbench or pin board, according to the dictates of the specifications of the shackle. When this is done, the collection can be fastened with tapes, cable ties or clamps according to the specification. The cable components are then fitted with suitable protective sleeves, conduit, protective yarn or any form of insulation. The production process for the assembly is now complete, and it can be fitted directly into the device of use or packaged to be shipped.

Step three

The next stage would be the testing of the efficiency and functionality of the painless wire bands. This is done with the aid of a test board. The circuit diagram data have been previously programmed into the test board, and each of the primary wires can subsequently be tested individually or as a collection.

Point to note

Despite the efforts at automating the process of harnessing, the most cost effective processes have been the manual ones. It is also possible to automate some parts like the cutting of wires, the crimping, and the soldering of wire ends, as well as partial plugging of wires into the connector housings.


wire harness usageIt is pertinent to inculcate the values of maintenance of all forms of electrical bit in order to achieve maximum performance from the systems in question. Then again, adopting the values will ensure safety. Maintenance can, therefore, be carried out by inspection, detection, and repairs.


How to Choose The Right Custom Cable Assembly

Almost everyone in the United States will come into contact with a cable assembly, whether they realize it or not. Many of those same people will then find themselves having to purchase a customized assembly. If you are a first-time purchaser, then you may be uncertain as to the process. There are numerous great tips out there to aid you in your search for a company that assembles cables:

  1. Communication skills matter.

This may surprise some customers, but engineering and manufacturing skills are not the only facets of cable production. A company’s customer service department matters greatly in the field of customized cable assembly. Every industry is different, and every household is unique. The success and efficiency of a cable assembly is necessarily dependent upon whether the manufacturer heard and understood what you had to say. So request a representative to meet with you personally to determine your plan.

  1. Ask to see a client list.

Experience is key, as faulty cable systems could cause immeasurable damage and potentially raise an issue of safety. Additionally, to ensure efficiency, you will want to know whether the company has worked with similarly situated clients. To gauge a company’s experience, look to past clients. Not all companies have this available, due to privacy issues. But it never hurts to ask.

  1. Have sketches ready.

Along the same lines of the theme of communication, it is best for you to come prepared. You should know where you want to install your cables, why, and what function they will serve. Bring any kind of paperwork you have that may help you communicate your needs to your representative. Remember to put down any questions you may have beforehand.

  1. Do not ignore the certifications of a company.

In many industries, certifications do not hold much significance. This is not the case in the electronic world. Certifications like the CSA International and the UL Registration indicate an ability to maintain industry regulation standards and comply with updated training processes. This is crucial, as it means a company is more likely to be efficient and safe.

  1. Be familiar with the environment in which you will place your cable assembly.

The environment in which you will connect your cables determines the construction and materials involved in your customized assembly. Hotter climates and exposure to sunlight demand that wires be encased in heat-resistant insulation. Other potential problems include contact with saltwater, the risk of water damage and vibration and shock exposure. Sometimes you will have multiple environmental factors present. It is important that you be able to share this with the company.

  1. Tour the facilities.

When searching for a company to manufacture your cable assembly, you should ensure that the company maintains facilities that are large enough to accommodate the process of cable production. Ask about outsourcing, as this can be a way for the company to save money by producing standard pieces elsewhere while saving customized parts for in-house.

  1. View the product list.

Finally, ask to see a list of the types of products the company manufacturers. This is a simple but important tip. Often you can gain a feel for a company’s proficiency in a product just by reviewing items they have made in the past.

Custom Cable Assemblies – How to Find a Sub-Contractor

As with any business partnership, when you are searching for a sub-contractor specializing in custom cable assemblies, you will want to weed out the good from the bad. Contracting a sub-par company will not only cause you stress and aggravation, but it can also quickly deplete company funds and drive away customers. With those real concerns in mind, here are 5 tips to help you find an excellent custom cable assembly contractor.

The first thing to look for in a company is a high level of integrity. Not only is it important that you select an individual or group of people who adhere to moral and ethical principles, but they should also be honest every step of the way. This relates to delivering cost-effective solutions that do not compromise laborers, drawing up fair contracts, and giving you top-notch products.

A second important point to look for in a business partner is an experience. The more experience a company has, the more you can learn from their track record and reputation in the custom cable industry. With experience comes knowledge about not only products but services such as storage, packaging, and delivery. Another benefit of working with a company has been around for a while is that they have more experience dealing with customer service and effective communication.

Of course, a contractor can have all the integrity and experience in the world, but if the quoted price is out of your budget, you will not be able to use them. This is why the price is a significant factor to consider when selecting a sub-contractor. To find out if a company’s services and products are within your means it would be prudent to request a quote or ask to speak to a technical specialist about your budget.

It seems like most things can be done online or over the phone. However, when it comes to picking up or dropping off your cable assemblies, you should take into account the physical proximity and convenience of a company’s facilities. You never know if you might want to meet with a representative or employee in person, and it is best to pick a location that is not out-of-the-way or located on the other side of the country.

The last tip for finding the best sub-contractor for you is to ask for references. You can do this in person, or by email or phone. A more informal way to collect references is to ask others in the industry what their experience has been dealing with a particular contractor. When researching online, you can also check to see if a contractor adheres to international and industry standards, as well as their credentials and certifications.

cable harnessingBy following these 5 tips, you will have an easier time of employing a high-quality custom cable assembly sub-contractor. Every tip is important, but there is also something to be said about chemistry. If you don’t feel confident about a business relationship, then move on to the next option until you find the best fit for you.

Sources used

Wire Harness Assembly: How Does it Work?

There are wire bindings all around you. From the ones running inside your computer or television set, to under the hood of your car. To put it in its most basic terms, a circuit of wires is a collection of cables or wires attached in specific ways to transmit electrical signals and powers.

If you have ever wondered how a cable assembly works, you have come to the right place! Here is your guide to assemblies in production and operation.

The Production Process

A cable feature is engineered according to the spatial-geometric and electrical requirements of the product. The result is a technical diagram to guide the set-up and assembly of the circuit by the production technician, who will usually receive some training on the exact assembly process.

Once the technician has selected the raw materials specified by the plans, he or she will cut them to the desired length, using a special stripping and cutting tool. With the wires cut and the metal core exposed at the ends, they are fitted into terminals or connectors. Often the ends of the wires will be inserted into an assembly board according to a specific layout, and then will be covered with a protective sleeve to form the harness.

Although technology in this industry has advanced greatly, much of the manufacturing is still being completed by hand. This is largely due to the variety of processes involved and the difficulty of automating those processes. Producing harnesses by hand is far more cost-effective than automation would be, particularly since many orders are custom-made and in small or varied batch sizes.

Parts of the Wire Harness

The actual working of a wire cable manufacturer is relatively simple. Within each wire is a conductive material, usually copper or a blend of copper and aluminum or tin, which transmits electrical power, or information in the form of an electrical signal. This wire is then covered with insulation to protect it from heat and the elements, shielding to prevent signal loss and interference, and jacketing to protect it from moisture.

Complex electronics like computers and automotive systems have many different electrical functions or programs, so each wire in an assembly often has a different purpose. Yet, letting a bunch of wires run loose around an engine compartment would be a bad idea.

Instead, they are bound together and attached to scaffolding running throughout the engine compartment, or case body in the case of electronic products. This ensures the wiring is non-intrusive and avoids any unnecessary shocks, vibrations, or heat.

Wiring Harnesses and Its Uses in Different Industry Sectors

This assembly comes in various options today as per their different areas of application. Read on to know more about them as well as how to use them in your area of operation for optimal benefit.

Wiring harness as the name indicates is a string of cables and wires that are used to tie down the informational signals or operating currents to transmit it to their destination. They are nowadays used in the electrical, electronics as well as the automotive industries. In this article, we would deal with them individually.

automobile wire harness

Automotive Wiring Harness

Automotive wiring parts have made the use of electrical components in automobiles a breeze today. And the technology has reached amazing strides in the last few years.

In fact, the wiring in automobiles industry has become a lucrative industry in itself. This feature is used in different types of electrical wires and components for producing, storing and distributing electrical current to other parts of the vehicle. Among its different functions are starting the engine; providing electrical energy for operating lights; for running air conditioners, dashboard clusters, fuel tank collection pieces wire connections to horns, music systems, and other devices. Apart from these standard uses, there are also varieties of customized solutions of these as well as power supply cord that offer other functions.

Electronics Harness

This variety is used extensively in all types of electronic gadgets. There are those that are made for computers as computer cables and data for effective data transfer. Then there are harness solutions for a flip flop and toggle applications. Control cable assemblies are used widely in the home appliances industry as well. Audio and television wiring assembly is also one of its many uses today.

Electrical Harness

The harness itself, is used most highly in the electrical industry. They are used in wiring in residential as well as commercial buildings. Then there are those that are made to supply electrical energy to control panels in various kinds of pumps, telecom components, and textile machines. Power joints connect cables of higher current rating from one machine part to the other. XLPE, HR cables are used for high current applications. Among the many other varieties of electrical components available are an electrical fuse, switches, fuse holders, wiring connectors, switch panels, and relay connectors.

Getting Wiring Harness Online

An online source is a great option for ordering the equipment. This is because here you can get access to a many reputed and established manufacturer and exporter of quality international quality products and customer specifications. You can also avail competitive prices that are prevalent in the world market while ordering other electrical items like power supply cord etc. however, before ordering products from the net, make sure that the company follows ISO 9001:2000 standards to ensure that quality products.

Importance of Wire Harnessing In Industries

A wiring and cabling system is used in all types of industries. There are many machines which are used and are interlinked. The cables are often bound with the help of materials which provide insulation. This process is called wire harnessing. This procedure is applied in several machines such as heaters, air conditioners, and cars. The cables are tied together by tapes or conduit. The loose wires of the different machines are brought together to make the place systematic. If the collection of wires are stretched, it can stretch to a couple of kilometers. It is done for shrinking the space requirement for the wiring systems.

Benefits of cable harness

The concept of the custom wiring harness is also called cable materials. When you bind a bunch of wires, you get many advantages. Moisture is the single biggest problem in cable connection. If moisture enters cables, they may not function properly causing short circuits. By bundling the wires up and putting a protective covering, the wires are protected against any moisture attack. Other factors like vibrations and frictions and also nullified by way of wire clamps. The protective layer makes the cables durable and provides a shield against any external harm. The type of protection you require can easily be decoded by customization to suit your working area.

Get an expert

Many companies are dealing with cabling jobs. You need to find out that which agency will suitable for custom cable manufacturing job at your location. Unless the company is proficient in this work, the job done at your place will not be protective enough for your machines. It may give away after some time, and let your cables get exposed to factors which may damage them. The cabling companies also offer a maintenance service of the job they do for their clients. This gives you added benefit by offloading the take care part of your cables, and your machines function without deterrence.

Enhances safety of workplace

When you are placing an order of these cables, you need to provide all necessary details to your vendor for helping them prepare the best output for you. The materials of the existing cables, their functionalities and heir specifications have to be provided to the cabling company to design the best harnessing for your cable parts. When you provide a casing to the bundles of wires, you minimize the chances of accidents caused by electrical shock. This basically renders a higher safety and reduces the hazards of electrical accidents. This is very appropriate for industrial establishments, as there are huge cabling systems which need to be organized and put into a protective jacket.

Go for cable harnessing without delay

The fastening itself is a boon the user of machine systems. It is even used in the PCs where the different wires are put into a single protective layer. This not only reduces the space but also minimizes the risk of electric shock hazards. Try to go for manufacturing with a reputable company like Wunsch Technologies, to increase safety and make the site visually appealing trough the covering of the multiple wires here and there.  We’ve also written a great article on the types of wire looms available on the market.  Check that out here.

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