Wire harness technology is used in many industries that require electrical operations. Installing a well-designed wire harness into a device, machine, or equipment can prolong the life of its electrical system. Since wire harnesses have been utilized in many sectors for about a century, it’s not surprising that the innovation behind designing a harness has evolved and adapted to modern technological advancements.
The main function of a wire harness is to act as a pathway for electrical signals to flow throughout the machine or device. Different components within the harness such as relays, connectors, and terminals, are responsible for guiding these signals to where a specific electrical operation is required. A wire harness also protects and reinforces the components within the electrical system making it more durable.
A typical electrical system consists of hundreds and sometimes even thousands of components depending on the device. However, Installing a wire harness can streamline the production process in many industries. Instead of individually installing the wires of a machine or device, manufacturers can simply install the wire harness as a single unit.
The Manufacturing Process
The journey of a wire harness begins with the process of designing a schematic diagram for the entire electrical layout. Engineers and experts use CAD software to draft a design for the specific machine that the wire harness is intended for. Changes are also common when it comes to conducting feasibility studies to ensure the quality of the wire harness design. After finalizing the schematic layout, manufacturers can then start the production process.
Most companies use software that ensures a standard quality when cutting and grouping different conductors. This allows the machines used by the manufacturers to work with great precision when measuring and sorting parts. The ends of the wires are usually stripped mechanically. This is necessary to securely connect wires to terminals or other components without the risk of falling apart once the device or machine is in use.
Companies today implement both automated and manual assembly processes depending on the specific type of operation. Machines can typically perform faster when it comes to grouping, cutting, and measuring conductors. For soldering and installing specific parts, companies still rely on skilled workers to efficiently assemble wire harnesses, especially in small batches.
Custom Wire Harnesses
The automotive industry is one of the biggest sectors that use advanced wire harness technology. Modern cars require sophisticated electrical systems that can keep up with today’s automotive trends. For many car enthusiasts, assembling a custom wire harness gives them the liberty to modify their vehicles with more features and capabilities.
The process of making a custom wire harness is similar to one that is made by a manufacturer. If you’re planning to build a custom wire harness, you must start with a schematic design illustrating the entire electrical layout. Once you’ve finalized the design, you can move on to the assembly process. Assembling a custom wire harness requires a lot of knowledge and patience. However, you can also consider submitting your wire harness design to a manufacturer so they can assist you with the assembly process.
