Space is optimized and the risk of an electrical short is reduced because the wires have been constructed into a non-flexing bundle. The risk of electrical fire is also reduced when the wires are bound within a flame-retardant sleeve.
A wire harness process is designed based on the geometric and electrical requirements of the equipment it is to be installed in. Once the initial design is established, a schematic is used to create the manufacturing paperwork and the assembly board for the harness. The assembly board, also called a pin board, is a full-size diagram of the harness which shows all of the components and their locations.
It also serves as the workbench for the harness. The wires needed for the harness are first cut to the desired length and labeled appropriately. Next, the ends of the wires are stripped to expose the uninsulated conductor and fitted with any required terminals or connector housings. The wires and components are then assembled on the pin-board to the desired specification and then bound together.
Wire harness assembly process is one of the few remaining manufacturing processes that is more efficiently done by hand, rather than automation. Our braiding, custom overmolding and potting capabilities allow us to design automotive harnesses for vehicles that will be exposed to any conditions: dust to mud, humid to arid, arctic ice to desert heat. Wire harness specifications for light and heavy vehicles have become more specialized due to increased electrical and electronic content; finding a global collaborator with an engineering team to work with from concept drawings to building and testing custom harnesses is a challenge.
This is because of its sequential line setup, which allows technicians to identify wiring harness problems early in the manufacturing process rather than later when cost and time become critical factors. Budgets have a tendency to dictate purchasing decisions, and when they do, teams will often opt for cheap materials, such as copper alloy, instead of OEM-grade copper for critical components such as wiring and terminals.
Even more important is the overmolding material used to protect the wiring harness from external elements. Inadequate overmolding is partly the result of poor design processes, which should take environmental factors into account when developing products. Making smart decisions about electrical components is not always a straightforward task.
More often than not, product teams will benefit greatly from the guidance and expertise of OEM engineers who are most familiar with the wiring harness manufacturing processes and capabilities.
Consulting with an engineer that specializes in wiring harnesses will ensure that the right questions and considerations are discussed before making design and order decisions. They also have the insights needed to avoid common wiring harness problems and maximize investments. When searching for a manufacturing partner that will significantly reduce the risk of wiring harness problems, look for the following trust signals:.
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