Wire harnessing is the production of ready-to-connect cables, cable bundles and complete wire harnesses with connectors, contacts or wire end sleeves.
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Today, wire harnessing is a special discipline of electrical engineering. The enormous abundance of cables, connectors and connection options has created its own industry within the industry.
The focus is not only on small series. Wire harnessing is used in applications in the electrical and electronics industry: from prototypes to fully automated mass production.
Definition
But what exactly is wire harnessing? Wire harness is more than just a single wire that connects point A to point B. Rather, it is an assembly that is connected to a mains connection, a filter or other components. It does not represent a separate device/product unit, but rather connects the customers’ components in a customized manner.
The task of Wire Harness
The task of wire harness is to connect one component (or assembly) to another in such a way that the technical, safety-related and also economic requirements of the connected final product are met. A very accurate overview of all the steps in wire harnessing can be found in figure 1. All these steps must be precisely defined. At first glance, this looks easier than it is.
Step 1 and 2: Selection of
components and terminal connections With the choice of the component, we determine the terminal connection with its respective advantages and disadvantages or application scenarios. For example, Quick Connect and screw connections are suitable for difficult connection situations with the need for subsequent assembly and can be detached with standard tools in case of maintenance work. A disadvantage of Quick Connect could be that they could come loose in applications with strong vibrations. Soldered connections, on the other hand, create a permanent connection, but must not be exposed to strong mechanical loads without strain relief. SCHURTER components are available with different terminal connections. For our application we choose a device connector with Quick Connect terminals.
Step 3: Wire connection
The type of wire connection was determined with the selection of the component in steps 1 and 2. For Quick Connect, for example, the question arises as to whether they should be uninsulated, partly insulated or fully insulated. According to our illustration, we select a fully insulated version.
Step 4: Wire type and colour
Let’s go back to our connector, which we want to connect to the power supply. Considering the electrical parameters voltage, current and power, we have to select the appropriate cross-section of the wires. How many wires do we actually need? Three as usual for an IEC connection? Do we want to work with stranded wires, or cabled wires? Do we want the wires to meet the UL standard for the US market? Do we need the European or the US colour coding for the cabled wire? What temperature range should the wires or the cable fulfil? In this example we work with three single wires.
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Step 5: Wire length
Step 5 is pleasantly simple: the length. Measure, define and plan for reserve. As short as possible, as long as necessary is a good principle. This keeps losses low, minimises space requirements and creates enough buffer for a proper installation without pulling forces.
Step 6: Wire end terminal
For the free end of the terminal connection, we have a variety of options. In addition to flat plugs, wire end sleeves or ring cable lugs are also available. Often customers simply choose an open end with partly stripped insulation, which protects the wires during transport until assembly. In other examples, terminal blocks or connectors are defined. We are happy to advise you on our wide range of options.
Why the effort is worth it
There is a simple reason why wire harnessing has become an industry within an industry. The variety of connection options is so large that specialised knowledge is required to determine which version is best for a given application. A second point: the customer can relinquish costly investments in tools, infrastructure, and specialised knowledge, because due to the numerous configuration options, most of the work is done manually. This requires reliable, qualified personnel.
Approvals
One more point: if you want to supply to the automotive or railway market, for example, you have to make sure that the company, where your wire harnessing is done, has the same certifications as the product to be connected.
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Often when sourcing electronics components, the words wire harness and cable assembly are used interchangeably.
In truth, the two are actually quite different. If you are sourcing electronic components for product development or manufacturing operations, here is an analysis of wire harness versus cable assembly, so you can discern the difference in the future. What is a Cable Assembly? Cable assemblies are composed of a wire cable, or a group of wire cables, covered by an exterior sheath. This sheath is usually made from shrink-wrapped thermoplastic, thermoplastic rubber, or vinyl. There are a number of different materials used for sheathing the cable, however what sets a cable assembly apart from other components is that the sheathing lies on the exterior of the cable. This layer is usually an additional sheathing around the rubber or plastic insulation that coats the individual wires within the assembly. This sheathing protects the assembly and the wires inside it from heat, friction and abrasion, moisture, compression and any other hazard the assembly might face. This makes it particularly useful for outdoor applications, since it is highly resistant to elements in the environment. For this reason, cable assemblies are most often used in industries where the cables will be exposed to the elements, such as military and oilfield electronics and major security installations. Additionally, many manufacturers prefer to use cable assemblies over wire harnesses because they are bundles into a neat, convenient package to make it easier to route cables around equipment and components. Connectors can also be molded and sheathed to optimize its protective qualities. The disadvantage of cable is that they are usually quite large and heavy. Also, the extra layer of sheathing usually necessitates a higher price tag for these components. What is a Wire Harness? A wire or conductor is usually made of a highly conductive metal such as copper. A wire harness is an individual metal strand, or group of metal strands covered by an exterior sheath. Usually this sheath is made from the same thermoplastic or thermoset material that serves as sheathing for cable assemblies. This is what sets wire apart from cable. The wire only has one heat-wrapped sheath around the conductive strands. Cable then takes those plastic coated wires, bundles them together and yet another sheathing is applied to the exterior. The advantages of using wire harnesses is that they are smaller and lighter, and can be sourced at a lower cost to manufacturing operations, since less material and labor are required. However, these are a poor replacement to cable when it comes to protection against environmental threats. Wires are poorly insulated and not secured, making it harder to snake them around various obstacles. Wire harnesses are often used in applications where the wire will be protected by an exterior shell. Primarily these are used inside products and equipment, such as computers, cars, and even airplanes.When designing new electronics or sourcing the best materials for your oilfield, military, security, and even healthcare operations, knowing whether to use cable or wire is critical to mitigating manufacturing costs. Additionally, having this knowledge will help you ensure that your products and equipment functions without fail.
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