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Wire Harnesses

Chapter 1: What is a Wire Harness?

A wire harness connects multiple point to point assemblies and combines them into one all inclusive assembly. They are held together by cable ties and a protective sleeve or sheath that shields their wires and wiring against the effects of hostile and hazardous environmental conditions, such as moisture, heat, and friction. Wire harnesses are used to organize breakouts to make routing easier through a system or box build.

The distinguishing feature of wire harnesses is their many ends or breakouts that run in several different directions. This allows wire harnesses to serve multiple functions due to the terminations on each breakout. Wire harnesses handle the energy and information flow in electrical and electronic (E/E) components to fulfill primary and secondary functions.

Modern electronics are becoming increasingly more complex and complicated, which presents a challenge in regard to managing breakouts, assemblies, and wiring connections. Wire harnesses keep wires organized and provide a systematic arrangement of wires in insulated material.

A wire harness is a simple, straightforward, and low-cost method for organizing a wiring system. They have an exterior sheath for protecting inner conductors or bundles of conductors. In essence, wire harnesses are an inexpensive and effective technique for organizing and protecting complex wiring.

A term for wire harnesses that was used many years ago was wiring loom, which has been used to refer to wire harnesses, cable assemblies, and wiring assemblies. The use of the word “loom” comes from making thread or yarn into cloth by weaving them. In essence, a wire harness has a similar construction since it is the weaving of wires together to form an electrical tapestry.

Chapter 2: How Wire Harnesses are Made

Wire harnesses are found everywhere from cars and trucks to rockets, jets, and airplanes. They are a systematic method for bundling wires to form an integrated unit. Wire harnesses are designed to transmit power or signals, connect components, and are critical to the performance of electronics.

The unique nature of wire harnesses requires a specific set of steps for their assembly. Unlike other components that can be mass produced, wire harnesses require careful planning and design configurations. To fit an application, their wires are grouped, organized and encased in sleeves made of material that is capable of resisting the effects of heat, moisture, dust, friction, vibrations, and various hazards. The organization of wires makes it easier to route circuits in limited space.

Designing

The design of a wire harness plays a critical part in the functions of machinery, automated systems, and manufacturing equipment. Wire harnesses are a significant part of the efficiency and safety of equipment. It is for these reasons that their design is carefully considered to ensure the uninterrupted operation of systems and the minimization of potential failures. Poor design can lead to system failures that can delay production, cause significant financial losses, and endanger workers.

Wire harness manufacturers produce their products in accordance with the technical guidelines provided by customers. The design process involves creating a customized solution specifically for a customer’s needs and requirements. Included in the design process is consideration of the type and size of wires, types of connectors, connections between components, and aesthetic and ergonomic specifications. An essential key to the process is the experience, skill, and abilities of the wire harness manufacturer.

The markings on a wire harness design reduce potential errors during installation and use. Each of the individual wires and its purpose is indicated by its labeling, which helps in repairing a wire harness when problems arise. Specially designed computer software has been developed that is dedicated to designing wiring harnesses.

List of Wiring Harness Software

• CATIA Electrical Harness Design is 3D software with tools for creating, managing and analyzing wiring harnesses.
• Mentor Graphics Capital is used for designing electrical and electronic systems.
• E3.series
• SolidWorks Electrical
• AutoCAD Electrical is a specialized version of AutoCAD with 2D design and a symbol’s library for electrical installations
• SEE Electrical creates schematics and technical drawings for managing data and generating documentation.
• Cadence OrCAD is a PCB design tool that can be used for designing wiring harnesses.
• EPLAN Electric
• Siemens NX Electrical Routing offers integration with 3D mechanical designs.

Wire harness manufacturers normally inform their clients of the type of software they use for designing wire harnesses. In most cases, engineers from the client and the manufacturer work together using the software as a visual tool. Partnership during the design process is critical to the successful manufacture of a wire harness, ensuring that the design will match the requirements of the function for which a wire harness is being produced. In certain instances, the choice of design software depends on a client’s needs and preferences and the industry that will be installing the wiring harness.

Bill of Materials (BOM)

The bill of materials for a wire harness is a list of the components and materials that are necessary to manufacture and assemble a wire harness. Included in the BOM is information about quantities and suppliers and has a technical drawing of the wire harness, which indicates where a particular component will be used. The creation of the BOM is dependent on the design software used to create a wire harness.

The BOM is a unique feature that is offered by wire harness manufacturers. In essence, it is a complete presentation of the materials and methods that will be used to produce a wire harness. The upfront listing makes it possible for customers to see every aspect of their wire harness from raw materials to finished product.

The purpose of the BOM is to serve as a reference for the various departments of a wire harness manufacturer. It ensures consistency and accuracy during the manufacturing process and helps with inventory management. The BOM streamlines the wire harness design process making it more efficient, reliable, and cost effective. It is an aspect of the wire harness manufacturing industry that has made the industry so successful.

Included in the BOM are:

• Wire and cable information about the types of wires, their lengths, sections and colors.
• Connectors is a list of the kinds, types, numbers and connection methods.
• Terminals, pins, and contacts includes information about components, their suppliers and how many are needed.
• Insulation and shielding is a list of insulating materials, shielding, and electromagnetic shielding.
• Mounting hardware is what will be used to assemble and secure a wire harness.
• Labels and markings includes a list of labels and markings used to identify wires or connectors.
• Gaskets and plugs lists any gaskets and plugs that will be used to seal a wire harness.

At the bottom of every BOM is a list of accessories that is unique to the structure of a wire harness. Since every wire harness is custom made, items in the accessories vary and can include switches, fuses, diodes, buttons, and other components that are required by the wire harness design.

Cutting and Stripping Wires

An electrical harness is cut according to the length of the wire and the length tolerance of the final product. For accuracy, the cutting process is completed using an automated cutting and stripping machine that completes the process quickly and efficiently. As with every aspect of the manufacture of a wire harness, the accuracy of the cutting process is essential. Automated cutting and stripping machines cut and strip every piece of wire to the required dimensions.

Cutting and stripping prepare the wires to be harnessed. Stripping removes the insulation on the wire to expose the conductive material. In addition, stripping prepares the wire for the attachment of terminals and connector housings.

With large numbers of conductors or when difficult materials are being used, the cutting and stripping process is divided into two stages with the removal of the insulation being the first stage, and the second stage is completed manually. The completion of the process includes twisting the conductors to achieve a non-frayed uniform end to the harness.

The other types of stripping and cutting machines are computer controlled, recognition and trimming, and multifunctional machines. Computer controlled cutting and stripping machines can be programmed to cut several cable lengths and sizes for any type of insulation. Recognition and trimming machines have sensors that recognize the length and dimensions of a cable bundle. Multifunction machines use different cutting tools to isolate and split cable bundles. Although these alternatives are available, automatic cutting and stripping machines for single core cables are widely used by the electrical and electromechanical industry.

Labeling and Marking

Labeling and marking help in the identification of the wires for a wire harness and their function. During the initial design process, customers work with wire harness designers as to the function of each of the cables in the harness. The agreed upon configuration is represented during the labeling and marking phase of wire harness production. The proper labeling of wires makes the installation of a wire harness easier and assists in locating wire harness failures.

A traditional method used to label and mark wires is color coding that uses colors to indicate the purpose of each wire. Although there are several colors used in the process, the five traditional colors are brown, blue, yellow or green, red, and black. In some cases, color coding does not supply sufficient information, and printed markers or labels are taped to the wires.

Adhesive labels are an economical method used for identifying wires on a wire harness. The critical part regarding the use of adhesive labels is selecting the correct label for a project. The most common materials are foil, polyester, and vinyl with vinyl being used the most due to its durability and conformability.

Aside from the materials used to produce wire harness labels there are three common types, which are wrap-around, self-laminating, and cable flags. Wrap around labels come in different sizes and can be printed on by thermal transfer or a laser printer. Self-laminating labels have a white printable area and a clear laminate tail that wraps around a wire and covers the printed information. Cable flags stand out like a flag and are capable of containing several lines of data but are less durable than self-laminating and wrap-around labels.

A third method used to identify wires is letters and numbers that delineates the conductor structure. Letter and number labels and markings consist of three parts with each part serving as a descriptor of the function of the wire.

• Letters indicate the structure and material of a conductor, the type of insulation and coating, and other information.
• The first number or digit is a description of the voltage rating of the insulation.
• The second number or digit is the number and section of the conductor.

The Society of Automotive Engineers (SAE) is an international professional standards organization that has specific requirements regarding the placement, types, and positioning of wiring labels. The organization does not have any legal force but is respected by several industries and manufacturing companies.

Crimping and Soldering Wire Harnesses

Every electrical wire harness has terminals and contacts of various kinds that are referred to as pins. The basic types of contacts are open barrel and closed barrel. The crimping of contacts can be performed manually with hand tools or by an automated press. The increasing demand for wire harnesses has made the use of automatic crimping machines necessary and more productive.

Automatic crimping machines have advanced programmable control systems and sensors that make it possible to customize the crimping process to the types of terminals, connectors, and wire. Wire harnesses produced by the process are of the highest quality and consistency. As with other automated aspects of wire harness production, automated crimping machines enhance the efficiency of the process while quickly performing the functions.

The types of crimping machines include hydraulic, pneumatic, and electromechanical. Hydraulic and pneumatic crimping machines have adjustments of pressure to produce consistent, high-quality connections. Electromechanical crimping machines are automated and programmable. They have exceptional precision and are ideal for high volume crimping that has strict quality standards.

Secure and reliable connections are an essential part of the function of wire harnesses. Crimping and soldering are the two most common methods for joining conductors and conductors and connectors. Soldering is the traditional method and has been used for many years. It involves melting a small amount of a metal alloy, the solder, to create a strong, dependable bond. Crimping involves compressing and deforming metal to connect components. Soldering is preferred for delicate connections while crimping connections tend to be more durable and are used for high performance wire harnesses.

Although soldering has been used for many years to create wire harness connections, crimping is more popular due to its consistency, flexibility, and heat and vibration resistance. The problems with soldering include wire fatigue and stiffening. The process for crimping is simpler, faster, and repeatable. The pressure of the crimping process is so great that the oxide layers of the metals being connected form a cold weld on a micro level. The formed connection is strong and reliable, which reduces the risk of failed connections.

Wire Harness Taping

The purpose of wire harness taping and bundling is to organize the types of wires and protect them from harm. It forms and shapes the wires to fix, group, and segregate them. As with other parts of the wire harness manufacturing process, taping and bundling simplifies installation and keeps the wires from becoming tangled for safe operation. In addition, along with labeling and marking, taping and bundling make it easier to identify, repair, and service a wire harness.

The types of ties or tape used to construct wire harnesses are selected in regard to the application where the wire harness will be used. As with other aspects of the process, an additional factor is the environmental conditions. Ties for harnesses are classified in three general categories, which are internal and external serrated and non-serrated. Internal serrated ties are used for standard wire harnesses while external serrated ties are used with wire harnesses that have sensitive and delicate insulation. Non-serrated ties are used as an organizational method for large diameter wire harnesses.

During the taping process, sheaths are attached to the assembly. Sheaths act as an outer armor of protection for wire harnesses. They protect the wires and assist in organizing them. Sheaths provided protection from abrasions, impact, and corrosion. They protect against harsh weather conditions and offer water resistance. The assembly of sheaths includes the strapping process, such as tensioned, artificial, and metal braids.

Assembly

Wire harnesses are assembled by hand using an assembly board that provides a method for sorting the parts and wires of a wire harness. As with each step of the manufacturing process, assembling a wire harness is completed very carefully in order to guarantee the effectiveness of a wire harness. The assembly board offers precision, repeatability, efficiency, and protection for the wire harness materials.

The manufacturers of wire harnesses use highly trained specialists to assemble wire harnesses. The process involves careful study of the schematic diagram, which serves as the map or plan for the process. Knowledge, training, experience, and precision are critical requirements for wire harness assemblers.

The process of wire harness assembly is difficult, complex, and time consuming. It requires close attention to detail and strict adherence to the stipulations of the wire harness design. Wire harness assemblies can be completed on a board a few feet long or on boards that extend across a room. The assembling of a wire harness is the final step in its construction. Placements and changes are examined to ensure the quality of the final product.

Quality Check

During every step of the manufacturing process, wire harnesses are checked and rechecked for quality and performance. For the protection of their customers, every high-quality wire harness manufacturer puts their products through a series of final checks to ensure the performance and integrity of their work.

Although the steps taken in the process vary between manufacturers, there are basic general steps that are used by respected companies.

Finished Wire Harness Inspection Steps:

• Visual – Visual inspection of wire harnesses, much like assemblers, is completed by professionally trained technicians with years of experience in the wire harness industry. Wire harnesses are examined for appearance, crimping, insulation, and labeling. Any defects are recorded for study.
• Functionality – The functionality aspect of the inspection process involves the use of an electrical cable tester, which is used for strength tests, potential circuit breaks, and wire continuity. A break strength meter is used to determine if a wire harness can withstand the stress of its function. A wire tester tests the strength, durability, and integrity of a wire harness’ wires.
• Insulation – Insulation testing is in regard to the safety of a wire harness and is used to certify that the insulation is made correctly and meets national safety standards.
• Labeling – The labeling inspection ensures that the wires of a wire harness are labeled correctly and properly identify connectors.
• Safety – The final step in the inspection process is an assurance that a wire harness is safe to use.

The description of the manufacturing of wire harnesses as outlined above is a general overview. How wire harnesses are assembled varies between manufacturers with every manufacturer having their proprietary method. It is essential for customers who are searching for a wire harness manufacturer to have a rudimentary understanding of the manufacturing process in order to initiate a dialog.

Chapter 3: Wire Harness Connectors and Terminals

Wire harness connectors and terminals join the ends of wire assemblies. They provide secure and reliable connections between wire assemblies and electrical components. Connectors and terminals come in a wide variety of configurations in order to meet the requirements of different applications, environments, and connections.

Wire terminals hold the wire and establish secure conductivity. They are referred to as pins, blades, sockets, and lugs, which are integrated into the body of a connector. The method of termination of a connector determines the type of connection, which can be crimp barrels, insulation displacement slots, solder cups, or screws.

Wire harnesses are classified as male or female with plugs being male and jacks being female. Backshells are used with circular connectors as protection from environmental conditions, stress, and electromagnetic interference (EMI). Backshells are commonly used with wire harnesses for military projects and aerospace in accordance with SAE regulation AS85049.

Wire Harness Terminals

Ring

Ring terminals are the most common type of electrical terminal. They have a simple design that consists of a metal ring with a hole in its center, which allows it to be fastened. Ring terminals are made from copper, brass, or aluminum and come with insulation sleeves. The advantage of ring terminals is the tight secure connection they create. The wide use of ring connectors is due to how easily they can be installed.

Spade

Spade or fork terminals have a U-shaped design that allows the terminal to be connected or disconnected quickly. Like ring terminals, spade terminals are made of copper or brass and coated with a corrosion resist layer. They come insulated or uninsulated depending on the application for which they are used. The wide use of spade terminals is due to how easily they can be installed.

Crimp

Crimp terminals are the most popular wire harness terminals. They include a barrel or sleeve that is crimped to the end of a wire. The different designs of crimp terminals include butt connectors, ring terminals, spade terminals, hook terminals, bullet terminals, and pin terminals. Crimp terminals are known for providing good conductivity and preventing wire pullouts.

Heat Shrink

Heat-shrink terminals are similar to crimp terminals but have a heat shrink insulation sleeve. As the sleeve is heated, it shrinks and conforms to the wire and terminal. They are used in applications that require water protection and a tight seal.

Soldered

Common soldered terminals have a metal barrel that is soldered to the wire. They form a strong connection ensuring excellent electrical conductivity. The solder shell forms a connection between the conductor and cup entry slot. The quantity of solder is controlled to avoid overflow. Solder terminals are designed as machined pins to be inserted into the connector body.

Insulation Displacement Connector (IDC) Butt Terminals

IDC butt terminals are connectors without crimping or wire stripping. They have sharp contacts that pierce the insulation of the wire to make a connection with the conductive wire. The process for IDC butt terminals removes the need for stripping insulation from wire to connect a terminal. The blade of an IDC butt terminal cold welds to the conductor forming a gas tight bond.

Screw

Screw terminals are a method for connecting bare wire to a circuit. They are designed for a narrow range of wires. Screw terminals have a metal block that clamps down on the wire to create a connection. A common use of screw terminals is in situations where connecting and disconnecting are frequently necessary.

Push-On

Push-on wire harness terminals or quick disconnect terminals can be male or female. The design of male push-on terminals includes tabs that provide connection with a female terminal. The female version has holes to accept male tabs. There are several types of push-on terminals making it possible to adjust them to fit any application.

The eight wire harness terminals described above are a sampling of the many types of terminals that are available. Other forms of terminals include bullet terminals, eyelets, flagged terminals, hook terminals, and various forms of custom terminals. The development of wire harness terminals is an ever-growing aspect of the wire harness industry due to the varied uses of wire harnesses.

Each of the different terminals has their advantages and disadvantages. Wire harness manufacturers select terminals in accordance with the requirements of a customer’s design. Since there isn’t a one size fits all, during the design phase of the manufacturing process, engineers carefully select the perfect terminal for an application.

Wire Harness Connectors

Blade Connectors

Blade connectors are the most common form of wire harness connector. They include flat blades that insert into a female connector. They are widely used in the auto industry, can handle high currents and come in different sizes to fit a wide range of wire gauges.

Pin Connectors

Pin connectors have a cylindrical pin that fits into a socket. They are used with computers and electromechanical devices because of their compact size and reliability. Pin connectors are resistant to vibrations, which makes them ideal for mobile applications and high shock environments. They come in several varieties including single pin, multiple pin, and dual inline pin connectors.

Circular Connectors

Circular connectors have multiple pins or sockets arranged in a circle in a housing. They are resistant to moisture, dust, and vibrations and are extremely reliable, which is the reason for their wide use. Circular connectors have a threaded coupling that tightens to form an exceptionally secure connection. They can handle high currents and a wide range of wire gauges. The capabilities of circular connectors have made them the first choice for military applications, the aerospace industry, and the manufacturing of industrial equipment.

Rectangular Connectors

Rectangular connectors are versatile and are ideal for applications with multiple wire connections. They have multiple pins or sockets arranged in rows in a rectangular shaped housing. Their high contact enables them to have numerous connections in limited space. Rectangular connectors are able to handle moderate to high currents and come in a variety of pin counts, sizes, and shapes. They can have different locking mechanisms added, such as screws, latches, and other forms to ensure a tight and secure connection.

Terminal Block Connector

Terminal blocks, connection terminals, or terminal connectors are modular blocks that have an insulated frame that can secure two or more wires. They have a clamping mechanism and a conducting strip. The structures of terminal blocks can be single pass through, dual level, and three level.

Single pass-through terminal blocks connect two wires in a wire-to-wire connection and are referred to as single feed terminal blocks. Dual level terminal blocks are designed to save space and have connection terminals stacked on each other. Three level terminal blocks have an extra level added to dual level terminals making it possible to have multiple connections in the same block.

Chapter 4: Wire Harness Wires

The central part of all wire harnesses is the conductive wires that are used for their construction. The first wire that comes to mind when planning a wire harness is copper wire due to its resilience and high conductivity. Although this may be the first choice, there are other types of wire that are used to construct wire harnesses and include nickel, tin, silver, copper alloys, aluminum, and fiber optic cable.

Wire Size

Wires for a wire harness are chosen according to their size or gauge. American wire gauges (AWG) are a standard set of sizes that begin with size one being the largest diameter wire. As the numbers get higher, the diameters of the wires diminish. The factors that determine the gauge of wire for a wire harness are the necessary current and the distance the wire must travel to reach a power source. A bigger gauge of wire, lower number, is necessary for powering applications with a high-power draw.

Types of Wire

The two types of wire that are most commonly used in wire harnesses are copper and aluminum. Wire harnesses for the auto industry are normally made of stranded copper wire due to stranded wire’s malleability and high electrical conductivity. Since each type of wire has different physical and transmittance properties, the selection of wire for a wire harness is critical because it determines the performance and quality of a wire harness.

The diameter of wire for a wire harness is selected according to a wire harness’s electrical load and level of resistance, expressed in ohms (Ω). AWG information assists engineers when they begin wire harness design since it is an indication of the known electrical properties of a wire.

• Copper Wire – Copper wire is the most common form of wire due to its thermal and electrical conductivity, tensile strength, creep and corrosion resistance, and ductility.
• Aluminum Wire – Aluminum wire is a good electrical conductor with mechanical properties. It is used as an alternative to copper due to the cost of copper. Since aluminum wire expands when electrical current passes through it, it is coated with corrosion inhibitors that work as antioxidants to stop corrosion and the effects of high electrical resistance.
• Stranded Copper Wire – Stranded copper wire is small strands of high gauge wire that are twisted together to create low gauge wire. Stranded wire has greater dissipation than solid copper wire, is more flexible, and is easier to route, which is the reason it is used in automobile construction. The complex manufacturing methods for stranded wire make it more expensive than solid copper wire. Stranded copper wire and solid copper wire each have their advantages and disadvantages. The choice between the two is dependent on design parameters and the requirements of an application.

Wire Color

Although not generally used, wire color has become a standard method for identifying the wires of a wire harness. Wire harness manufacturers use several methods to identify wires in a wire harness. In most instances, the colors of wires are used for the most basic type of wire harness with the various colors identifying the functionality of each wire.

Wire Insulation

Since much of the work in regard to wire harnesses focuses on safety, the insulation of wire harnesses is a safeguard that is built into wire harnesses to protect the assembly and operators. The selection of the type of insulation is dependent on the exposure of a wire harness to moisture, temperature extremes, acidic chemicals, and the conditions where a wire harness may be used.

Wire harness wire insulation:

• Polyvinyl Chloride (PVC) is inexpensive and durable. It is used for low to medium voltages.
• Polyurethane (PU) shields wires from moisture and abrasions.
• Thermoplastic Elastomer (TPE) is elastic and resistant to cracking.
• Thermoplastic Vulcanizate (TPV) has superior compression set and thermal stability.
• Polytetrafluoroethylene (PTFE) is versatile and performs well in extreme temperatures and wet environments.
• Silicon insulation has heat resistance over a wide thermal range.

There are many factors to consider when choosing a wire harness manufacturer. The key to the process is selecting a company that specializes in the type of wire harness you require. Since wire harness manufacturing is complicated, delicate, and complex, working with a knowledgeable manufacturer is a necessity. They know the length and resistance required by a wire harness as well as the wire size and amperage needed. From initial design to completed product, wire harness manufacturers carefully oversee every step of the process to ensure quality and compatibility.

Chapter 5: Wire Harnesses vs Cable Harnesses

A common assumption is that wire harness assemblies and cable assemblies are interchangeable. Much of the confusion arises from the features that each assembly has and other similarities. The fundamental difference between the two is their main materials, which are wire and cable. Wire is solid or strands of material that conducts electricity. Cables contain two or more wires that are bonded or braided together, which gives the impression of being bunches of intertwined wires.

Wire Harness

Wire harnesses bundle up insulated wires. They contain multiple wires and are a low cost electrical solution that helps organize electrical systems. The bundled wires make it possible for engineers to identify the wiring in a system. Sheaths of wire harnesses provide basic protection and assist in the installation of cables and wires.

The main function of a wire harness is organization with protection being secondary. Wire harnesses are unable to shield wires from extreme temperatures and friction. They are an indoor type of electric solution. Unlike a cable assembly, wires from a wire harness are easily seen and can be removed.

The basic functions of a wire harness are to protect wires from harm caused by the flow of electricity. They are a convenient and efficient method for organizing wiring systems to make installation easy. Wire harnesses provide information to technicians for making connections and repairs.

Cable Assemblies

Cable assemblies are able to endure hostile and extreme environmental conditions. They have resistance to heat, dust and moisture. Cable assemblies are wires that have been tightly bound together and wrapped in a heavy insulation material. Once they are assembled, their wires cannot be removed or changed without a great deal of effort.

The exterior of cables is made of heavy duty material that is shrink wrapped over the wires of the cable. They come in a wide assortment of shapes depending on the application for which they are made. Cable assemblies can endure heat, friction, moisture, abrasions, compression, and an assortment of hazards.

The primary function of cables is to encase wires and protect them from harsh and stressful environments. As with wire harnesses, cables organize wires for easy installation but cannot be changed once compressed into a cable. They protect against any harm that may arise from electrical flow. Cable assemblies are more expensive than wire harnesses due to the cost of the materials used to produce them.

Chapter 6: Applications for Wire Harnesses

The uses for wire harnesses includes an endless number of manufacturers and industries that depend on wire harnesses as a safe and effective method for conducting electrical power. Included in the long list of wire harnesses are custom made harnesses that are designed to meet the unique requirements of an application.

Automotive Wire Harnesses

Any discussion of wire harnesses begins with the auto industry that depends on wire harnesses for transmitting power and signals to every part of a vehicle. Modern vehicles are equipped with a wide range of electronics that control different functions. Included in vehicle wire harnesses are aluminum harnesses, electric parking brake (EPB) harnesses, optical harnesses, and antenna harnesses.

Agriculture

Modern agriculture uses a wide variety of heavy duty equipment to harvest crops and feed cattle. Wire harnesses are a vital part of combines, harvesters, tractors, balers, and other farm machinery. Bound together and protected from the stress of farm work, wire harnesses ensure that heavy machinery performs as needed, regardless of the conditions.

Communication Systems

In communication systems, wire harnesses help optimize the use of space for telecommunications equipment, such as modems, routers, repeaters, and other broadband equipment. Many of the wire harnesses for communication systems are custom designed to adequately meet the unique features of a system. The process is necessary to provide a perfect match with existing hardware and protects against system failures.

Healthcare

The rapid rise of electronic technology can be easily seen in healthcare. The plethora of devices that can read nearly every aspect of the body are used to help maintain life and improve treatments. As with all electronics, wire harnesses provide effective electrical power ensuring reliable care. The versatility of wire harnesses enables them to perform many functions when treating ailments.

Manufacturing

As with many aspects of modern life, manufacturing relies on electronics to control, regulate, monitor, and operate equipment. From presses that shape transmissions to ones that form cooking utensils, every form of industrial equipment depends on the signals transmitted by wire harnesses. Assembly lines and production systems have intricate wiring systems that require wire harnesses to organize them. Wire harnesses take elaborate connections and streamline them to the requirements of the production process.

Conclusion

• Wire harnesses are the foundation of most modern electronics. They ensure efficient and safe conduction of electricity between components.
• A wire harness is a covering or sheath that protects bundles of conductors. They are a method for organizing wires.
• A key factor in wire harness design is identification of the wires in a wire harness. Labeling and marking of wires in a wire harness makes them easy to install and repair.
• The process for manufacturing a wire harness begins with a collaboration between customers and manufacturers, where specific data and details is used to construct a wire harness.
• Wire harnesses help engineers create orderly, carefully fitted wires into any application regardless of the type of environment.