Wire Harness – Why & How?

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Wire Harness Why How?
A typical wire harness may comprise of as few as
three components, or go up to dozens of wires
and hundreds of different components and
terminations, with multiple branches running off
in many different directions, having multiple
terminations on each branch. Whatever the count
and complexity, a wire harness is typically
designed to simplify the manufacture of a larger
component, designed based on the geometric and
electrical requirements of the equipment it
needs to be installed in. Manufacturing a wire
harness The design of a wire harness depends upon
the application in which it needs to be used.
Once the design is established, a schematic is
developed and paperwork completed, which shows a
full-size diagram of the harness, with all the
components and their locations clearly listed,
serving as the workbench for the harness to be
built. Working on this schematic, the process of
manufacturing begins. The wires are first cut to
the desired length, and then stripped to expose
the uninsulated conductor, after which they are
fitted with any required terminals or connector
housings. These wires, along with their attached
components, are then put on the pin board and
bound together with the help of cable ties, cable
lacing, tapes, sleeves, or any other possible
technique. The processes involved may either be
manual or automated, depending upon the
requirements and the complexities involved.
However, manual production remains more
cost-effective than automation, especially when
small batch sizes are required.
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Once the wire harness is constructed, it is then
tested for performance and quality. The testing
process involves everything from visual
inspection to mechanical testing, and electrical
testing. All these tests are done to ensure that
the entire wire harness is built properly,
without any cuts or faults. Along with that, the
tests also ensure the durability, strength, and
performance of the wire harness. While final
testing of the wire harness is important, many
manufacturers also perform testing at the end of
every individual manufacturing phase, so as to
find faults early in the process, to avoid any
hassles or additional costs at the end. Miracle
Electronics is one such industrial wire harness
manufacturer in India, with almost three decades
of experience in innovation and production of a
variety of wire harnesses like flat, ribbon, EMI
shielded, RF, airborne, and military. The
engineering staff here is well-versed in the
design and construction of wire harnesses,
capable of assisting in the development of the
most efficient harnesses to meet your
demands. Why choose a wire harness over multiple
wires? Wire harnesses are used in a variety of
industries like electronics, electrical
appliances, automotives, construction machinery,
and industrial equipment. By integrating all the
wiring into a single unit (or several units if
the number of wires is more), wire harnesses
simplify the construction of these larger
components with drop-in installation. Not only
does this process reduce the number or wire
units to be installed, but it also makes it
better secured against the effects of abrasion
and vibration, by constricting the wires into a
non-flexing bundle. Also, the effects of
moisture, chemicals, and shocks is eliminated,
thanks to the outer protective covering. Last
but not the least, with wire harness(s) in place,
the usage of space is also optimized.