What Is a Cable Harness?
A cable harness, also known as a wiring harness, is an assembly of electrical cables. Its purpose is to transport electrical power and signals from one place to another. Most cables are made of copper or tinned-steel wire, and they are often bundled in a single unit called a “harness”.
Wire harness
A cable loom, also known as a wire or cable-harness, is a bundle of electrical cables connected together for power or signal transmission. In general, a wire loom consists of about 10 cables, and its length depends on the type of electrical system it is connecting. This bundle of cables is called a cable harness, and it is the most common type of electrical loom for automobiles. However, not all harnesses are created equal.
When designing a wire-harness for your cable loom, consider how it will be used and where it will be placed. You’ll also want to consider any environmental or safety requirements. WHMA is a great resource for all things related to wire-harnesses. Contact us today to find out more. We’re happy to answer your questions. We can provide samples of wire-harnesses for you to inspect.
Wire assemblies are a common component of cable assemblies. While these cables can be as simple as male-to-male coax cable, a wire harness can integrate multiple breakouts and various types of cable assemblies. Wire assemblies are also used to connect two or more PCBs. For these purposes, a cable assembly is the most effective option. It’s lightweight and compact, and it saves time and money when compared to installing individual cables.
The process of producing wire and cable harnesses can vary depending on the electronics used in the device. Since these harnesses are a customized item, the options for customization are almost endless. However, wire and cable harness manufacturing is still a highly manual process, involving the use of tape, clamps, and cable ties. Automated methods haven’t replaced this process, and small to medium-sized suppliers still use manual methods. However, these manual processes are more efficient for small to medium-sized orders.
As for cable assembly and wire harness, both are different products that help organize wires. Wire is a single strand of conductive material, such as copper or tin. Wire harnesses are used to bind wires together in a bundle, and cable assemblies are a bundle of wires wrapped in a protective outer sheath. So, while cable assemblies and wire harnesses have similar functions, they are made to withstand different environments.
Cable assembly
The term cable harness is often used interchangeably with wire or wiring. Essentially, a cable harness is an assembly of electrical cables used to transmit electrical power and signals. The main purpose of a cable harness is to ensure that signals are delivered correctly to the intended destination. To understand its importance, let’s look at a few common examples. Here’s what a cable harness looks like. And how does it work. Read on to learn more.
During the production of an electrical circuit, time is of vital importance. To ensure that the production line runs smoothly and efficiently, special operational managers are appointed to check for inefficiencies. Using a cable harness assembly machine ensures that the assembly process is easy and fast and does not require the expertise of a highly skilled individual. This also means that time can be saved. With a little bit of practice, anyone can install and test a cable harness assembly.
OEMs often use cable assemblies in their own products. But they typically build them by hand using heat guns, crimpers, strippers, and other tools. This method is time-consuming and expensive, so the OEM eventually hires a contract manufacturer to lower costs and increase volume. However, outsourced harnesses may lead to a number of problems, including delayed deliveries, scrapped harnesses, and additional time and effort spent on fixing documentation.
A cable harness assembly has many benefits. It prevents physical trauma to the cables and reduces the risk of electrical shorts. They also prevent wires from being damaged by friction and extreme temperatures. Furthermore, the cables and wires are protected from damage due to vibrations and damaged spots. So, when you’re using a cable harness, you’re sure to get the best possible results. These advantages outweigh the downsides. It’s best to consider a wire harness assembly before you buy one.
The process of creating a cable harness is varied depending on its design. A cable harness begins by collecting the appropriate wires. They’re cut to the right length, stripped of their sheaths, and then fitted with connectors and terminals. These wires are then bundled together on a pin-board and bound together. The production process can take a few days or even weeks, depending on the complexity of the wire harness design.
Chemical resistance of cable harness
The chemical resistance of a cable harness is critical for the cable assembly, which may come into contact with a variety of chemicals. Additionally, a cable assembly must have a high tensile strength and abrasion resistance, and should be protected from wire exposure to chemicals. Cable assemblies should be covered with a durable heat shrink tubing for protection. This type of protective cover comes in many varieties, with varying degrees of heat tolerance.
Other features of an effective cable harness are a high strand count wire, a flat black finish, and corrosion-resistance. Depending on the intended use, materials may also be selected based on appearance or chemical resistance levels. During the prototyping process, customers may request substitutions or changes in leadtime. However, the benefits of high quality cable harnesses will far outweigh the drawbacks of low price.
Regardless of your use, a high-quality cable harness is important for the long-term performance of your electrical system. SAB Brockskes uses a variety of different materials in its cable harnesses, including different sheaths and insulations. For instance, cables that need to be chemically resistant are typically used in chemical plants, water treatment facilities, and industrial painting applications. Other options include modified PVC, polyurethane, PE, and Besilen(r) materials.
Fluoropolymers are another option for high-end wiring. These materials offer a variety of benefits, including longer lifespan, better performance, and reduced maintenance costs. Fluoropolymers are also chemical-resistant, but wire insulation can still corrode due to exposure to certain chemicals. If the wires are corroded, they can affect the electrical performance of the system and cause project failure. Fortunately, Miracle Electronics offers custom wire and cable assemblies.
Post-production testing of cable harness
To ensure quality, post-production testing of cable harness is crucial. A fully tested harness may not need additional testing during the installation stage. Quality manufacturers use test fixtures to ensure signal integrity. Often, wiring harnesses can contain many wires with multiple terminations, including contactors, Zener diodes, and LEDs. This means that manual testing is often insufficient, and may not be able to keep up with production output.
Performing thorough post-production testing is a must for harnesses, as it ensures their quality and safety. Harnesses are tested for their durability and effectiveness, as well as to ensure that the wires are safe for use. For example, if a cable harness is not coated with a high-quality, durable coating, it will be prone to micro-fretting. Additionally, intact plating prevents oxidation.
High-voltage testing is necessary for cables that will be used in aircraft and military applications. Some cables, such as those used for data communication, may never be subject to high voltages. In such cases, high-voltage tests are not necessary. For example, cables used for data communications are unlikely to carry voltages above 24 V. However, in the aerospace and military industries, safety is the primary concern. Dielectric breakdown detection is one of the most common test requirements. These tests can be conducted with 1,000 to 1,500 VAC/VDC.
Electrical testing is another important type of post-production testing for cable assemblies. These tests check for open wires, improper wiring, and shorting risks. Electrical fixtures can also check for the correct dimensions of a cable assembly. Signal integrity testing measures how strong a cable assembly is. It looks for crosstalk and signal errors. Additionally, it evaluates connectors and filters for signal strength. In addition, post-production testing also includes identifying problems that occur intermittently.
While manufacturing processes have become increasingly automated, manual production is still an important aspect of cable harness assembly. When hiring a cable harness manufacturer, look for a team that has extensive experience in wire cutting, stripping, and cleaning fiber. A skilled team will have a proven track record for testing the entire assembly to ensure electrical safety. Furthermore, they will conduct post-production testing to ensure the harness meets the signal specifications that the customer needs.