As years go on, our company become a professional wire harness manufacturer in China. We can provide all kinds of wire harnesses or custom wire harnesses for computers, internet routers, technology devices, vehicles, appliances, medical devices, heavy equipment, printers, lighting fixtures and etc.
With the professional wire harness design and manufacture team behind, we sure can make and supply the best wire harness for your specifications. Please feel free to tell us your demand, we will give you the best wire harness solution.
Wire Harness Design
Wire harness is the backbone of electronic products, it can transfer data and electric signals, extend the distance between different units inside machines. Its function is like the human body’s nerves and veins that can transfer information quickly with high stability. The initial stage in designing a wire harness package involves detailed study when engineers talk to Customers and evaluate how each part of the system must work together seamlessly during operation under normal conditions as well as under abnormal situations such as temperature changes or short circuits from electrical surges. Wire Harness manufacturers should have some knowledge about the product they are making to meet customers’ needs within a specific performance benefit by understanding their requirements thoroughly, after which the final design will be evolved.
For a wire harness to be functional and long-lasting, it must be designed with care. The wire harness design is the most important phase of manufacturing a quality product that meets customer requirements. Engineers use a wiring diagram during the design of a wire harness for a vehicle or machine. This diagram indicates where each electrical component will be located as well as how they connect electrically.
Designs vary greatly depending on the type of application involved; however, the following steps are common to almost all designs:
- Determine equipment layout and identify functions
- Prepare cable run list (stating length and size of wires required for each cable run)
- Layout cables on paper or on a computer-aided design (CAD)
- Create a harness diagram with reference to each component, terminal, and connector
- Identify wire numbers or trace codes for use in the fabrication of harness
- Design terminals and connectors necessary for proper operation
- Test and review drawings
Wire Harness Manufacture/Fabrication
Once the design is complete, it must be converted into a functional product. This conversion process involves several steps:
- Designing tooling to form parts (using metal dies to form metal parts such as terminal lugs and connectors, depending upon the material being used; normally, plastic parts are made using injection molds which can also be designed using CAD software).
- Tooling for wire wrapping operations (wire wrapping machines are used to bundle groups of wires into the harness).
- Creating tooling for cable assembly to terminate/connect cables. This is dependant upon the type of connection being used. For example, crimp connectors, terminal blocks, or soldering points will require different tools. Connectors can be designed using CAD software and then 3D printed as tooling by a mold maker before being sent to a contract manufacturer who does the final assembly producing the finished product ready for testing.
- Product assembly – The parts fabricated as above are now assembled together into various configurations depending on customer requirements; this can be done manually with hand tools or by using machinery and robots, which reduce errors and improve efficiency.
Wire harnesses are usually assembled into the following configurations, depending on customer requirements:
For vehicles and machines:
These configurations may be further broken down to meet different functional requirements, such as: for example, the fuel rail assembly used in a car (see above) is made up of several sub-assemblies which would be contained in their own harnesses. Many variations are possible; it is best defined at the design stage with the customer inputting as much information as possible to ensure that their needs are met fully.
Wire Harness Manufacturer
Wire harness manufacture is not a complicated task, but the complexity of making wire harnesses depends on how well engineers can work with one another and manage workloads. Although there are advanced technologies such as computer-aided design (CAD) tools to aid in designing wire harness prototypes, most designs are created by hand using pen and paper. Through repetitive practice, engineers gain experience in creating wiring systems that adhere to stringent requirements for lengths, materials, and performance requirements while minimizing costs associated with the assembly.
Wire Harness Testing
A complete production test must be conducted before a finished product is shipped. First of all, reliability tests should be carried out to check whether the products meet customer’s standards. These standards include mechanical reliability, environmental reliability, the safety of operation, and human body electronic system. It should be tested for its long-term performance or hardiness in the workplace and real-life situations. Besides, some specialized tests such as EMC (electromagnetic interference) tests are also necessary to avoid noise while data transmission or other problems like the product can break down at random, which may result in damage to equipment and even people’s lives.
Wire Harness Application
After manufacture has been completed, the wire harnesses are ready for use. They will typically undergo several tests such as:
- Loop resistance test – This ensures that there is no current leakage and that wiring insulation can withstand high temperatures without failing, among other things.
- Insulation resistance test – This makes sure low voltage wires aren’t affected by higher voltages nearby (which could cause a short)
- Anti-crash resistance test – This makes sure the harness has the strength to endure a crash.
- Charging capability test – This ensures that voltage can flow into one component and out of another without being affected by any other electrical devices in between.
- Lighting failure test – The lights within a wire harness are checked for faults, such as short circuits.
A wire harness is used in electronic devices and vehicles to connect multiple parts together. A wire harness will consist of; wires, connector(s), terminal(s), or lug(s). Wire functions determine how it is fabricated to make up a functional object. For example: if you want your car to stop when you brake, your wire harness will have a connection that detects this action and tells the car’s braking system to release. Wire harnesses are used for all electronic components in vehicles today.
Although nowadays wire harnesses are usually made of wires and connectors alone, often referred to as simple wiring or wiring loom; some special complex assemblies can also be produced using cable: for example, if a component needs to be mounted in an awkward place, then wire bundles may not be strong enough so they will need support – producing such assemblies requires extra care because there is more complexity (more cabling) than just the basic wiring that could go wrong.