Wire Harness Manufacturing Process 

A wire harness is referred to as the most crucial electrical and electronic component, and especially in the present modern world. The wire harnesses refer to bundled processed wires comprising a protective covering that helps you guard against any wear and tear caused due to environmental conditions and similar potential damaging factors. 

Wire harnesses are laid out while being built on a panel with pegs positioned in the right strategic manner where wires branch out in specific directions. In this way, the harness gets laid out in the appropriate dimensions. 

The task of manufacturing a wire harness is a challenging and time-consuming task. However, there are professional electronics engineers who make it a smooth process for you. There are companies of wire harness manufacturing that provide services to complete the entire wire harness assembly. 

These professionals perform on-site services, which include stripping, cutting, soldering, crimping, and more while assembling the wires in a wide range. The wire harness assembly is responsible for maximizing efficiency by slowly binding the wires together in a secured and safe environment by utilizing wire management products such as PVC, tie wraps, split loom tubing, and the like. 

What are wire harnesses beneficial for?

The wire harnesses offer a comprehensive range of benefits, such as the following: 

• Optimizes space and groups the wires together 
• Offers extended service life on wires and cables 
• Helps to facilitate the customization for any application requirements 
• It helps to improve the safety of equipment associated 
• It is available in a wide collection of varying lengths and sizes 

Application of wire harnesses: 

Automotive: 

The cable harness is useful in vehicles for a wide array of purposes, including signals, relaying information, along with electrical power. 

Flight simulators: 

This industry is known for using wire harnesses to transmitting energy and other information in close accordance with the standards and spacing requirements. 

Heavy equipment: 

Wire harnesses get incorporated in most of the heavy equipment, which is primarily used in construction along with varied other industries. 

Flat-panel displays: 

The flat screens that are a common sight in every home today are incorporated in order to keep the wires organized while mitigating electromagnetic interference. 

Ruggedized computers: 

These computers are largely used in military environments and in harsh industrial environments. These are known for incorporating wire harness and cable assemblies to safeguard and protect the internal wires from any exterior components such as moisture, dirt, dust, and the like. 

Apart from these, there are varied other industries and facets where the wire harnesses are used. These are exclusively seen in industries such as construction, appliances, electronics, heavy industrial pieces of equipment, medical equipment, the defense industry, and much more.

What do Your Contract manufacturers need for the Wire Harness Manufacturing Process?

The contract manufacturers are professionals who build both wire harnesses and cable assemblies. In order to create a differentiation between the two, they make use of a cable assembly, an external connection to devices with distinctive environmental considerations. Such considerations include insulation type, thickness, and flexibility. 

On the other hand, a wire harness is responsible for offering connectivity between systems in the perfect electromechanical assembly. This includes connecting a power supply to the motherboard. The wire harnesses get laid out while they are built on a panel with pegs being positioned strategically, with the wires branching out into specific directions. In this way, you can achieve the harness being laid in the exact dimensions as are required. 

It is recommended that you specify the dimensions, with the contract manufacturers availing a detailed pool of information to work with. Such pieces of information can be anything, from a handwritten note or to a series of complex models. It is important to note that the more detailed information you provide, the lesser problems you will face in the end product. 

Here are a few of the most informative pieces of data that you must provide during the wire harness manufacturing process: 

• A comprehensive detailing of the images of the connectors pinpointing the locations 
• A bill of the materials comprising the part numbers 
• The wire lists which specifies the nets, the wire colors along with the connector pin-outs 
• Specifications outlaying the finished harness test details 
• Drawing of a whole assembly comprising detailed information such as assembly instructions, label locations, and tolerances 

The Dos and Don’ts of Having Your Wire Harness Built:

Before going forward with the cable harness manufacturing process, it is necessary to know the dos and don’ts of having them built. Here are the most important dos and don’ts that you need to pay heed to. 

The electronics engineer is responsible for offering termination recommendations for how the wires need to be attached. It is a must to make most of the recommendations, such as tinned, stripped, and the like. This is exactly what the component is made explicitly for. This is similar to the torque values on fasteners, where you need to utilize the recommended values of the manufacturer. 

At the same time, it is a must for you to state out a few generic specifications for wires, including 300V or 600V, and no specific UL code. This offers CM the flexibility and ability to use the component that works the best for harness requirements, readily available, and cost the one that costs the least. However, the specific UL-coded wire is not essential for the harness and can be strenuous to find or even expensive to utilize. 

Lastly, make sure you reach out to the right manufacturer to get the specifications conveyed. At the end of the day, it is professionalism that matters!

Best place to go for wire harness manufacturing: 

It is ideal for visiting a professional wire harness manufacturer to avail the right service and professionalism. A wire harness manufacturer is a business or a company that offers services to complete the assembly process. This assembly of cables, wires, and connectors helps transmit the signals, electric power, and more. 

Complete on-site services comprise stripping, cutting, soldering, and more, which maximized the efficiency through binding the wires together. The industry standard for the manufacturers is the IPC-620 certification. The manufacturer is professionally trained to further train people in close adherence to the standards while having the process controls in the best place. 

The standard furthermore prescribes the industry’s best practices and requirements for the manufacture of wire harness assemblies. In addition to this, the standard entails that the tests, the materials, and the criteria for manufacturing mechanically secured wire harnesses are met well. 

Call to action:

If you need to avail of wire harness manufacturing, make sure you reach out to WellCircuits Electronics Services, the professionals known for delivering top-quality manufacturing requirements. We are well versed with the requirements and the norms that they need to follow. 

By adhering to your specifications, the professionals ensure to endeavor the manufacturing process accordingly. All you need to do is to get in touch with the experts, either through an email(sales@wellcircuits.com) or by calling the experts. You can also avail the best deals when working with genuine professionals onboard. Hence, feel free to get in touch today to avail the best benefits.