The humble cable harness is an unsung hero of electronics products, quietly doing its work to keep wires connected to power sources and linking components to ensure smooth, reliable, continuous operation. Cable harnesses organize and streamline wires within products and are critical to long-term performance. Cable harnesses may seem simple, but as products become more sophisticated and components continue to shrink in size, they are becoming more complex, able to work in challenging environments that require corresponding sophistication in design and assembly.
Simple design principles amplify the benefits of wire harnesses. Sheaths protect wires against abrasion or exposure to hazards, minimizing the risk of failure. Connectors, clips, lacing, and other organizational elements reduce the space that wiring needs and ensure that technicians can easily locate components when needed.
Given the important role the cable harness plays in electronics devices, choosing a strong cable harness manufacturer is critical to product quality and performance. Here’s what to look for in a manufacturing partner.
No surprise here. The best cable harness manufacturers are usually the most experienced. While that may seem obvious, not all experiences are equal. For example, different industries have different safety and compliance requirements. Cable harnesses in the medical device industry must use approved components (wires, cables, interconnects, terminals, etc.) and meet high quality and performance standards. The automotive industry has its own material requirements for harnesses, due to high-temperature engine applications and the presence of corrosive gases and liquids, vibration, and exposure to outdoor elements like rain and snow. So make sure that your cable harness manufacturer has experience and a strong track record in your industry.
Close behind experience comes certifications as an important consideration for selecting a cable harness manufacturer. Manufacturers must comply with the markets’ regulations and demonstrate a track record of creating products that pass industry testing labs. You should expect your manufacturer to have the necessary certifications for producing the type of cable harness you need. These include:
IPC/WHMA-A-620 is the most widely recognized standard for cable harness manufacturing and the most important certification for a manufacturer. Adhering to this standard ensures product quality, reliability, and consistency.
Cable and harness assembly typically requires connecting different wires to enable electrical current to travel through the connection. The most common methods of connecting wires are soldering and crimping. Both processes help create secure connections for cables, and they produce long-lasting and high-performing cable connections.
Crimping is the process of installing connectors on the ends of cables using a crimping tool, and involves stripping, cutting, and crimping terminals on either side of the wires. Whether manual or automated, proper wire crimping requires specialized tools and materials and must follow certain steps. High-quality crimps form gas-tight joints, which result from compressing specially designed splice bands or crimp terminals with cables and wires. Gas-tight connections prevent corrosion from moisture and oxygen.
Terminal crimping reshapes the strands in a wire to form a low-resistance electrical connection. The connections must be strong, with a single joint that has no breaks or segments, and the crimp must meet the height and width specifications established by the terminal manufacturer. It is important to avoid overly tight connections, as this can reduce the cross-section of the wire.
Soldering is a traditional wire termination method and can be more cost-effective than crimping. With this method, alloys of tin, silver, or lead are heated and used to create durable joints that connect contacts to wire conductors. Soldering is commonly used in applications that require dependable power and signal connections.
While soldering offers certain benefits such as affordability, some disadvantages of soldering include:
Make sure the manufacturer you choose has an experienced engineering and production team capable of producing cable harnesses that meet design specifications and maintain high-quality standards. For example, one of your first decisions is whether to use automated or manual cable harness assembly. You can automate some steps in cable harness manufacturing, but manual production remains common. Automation is used more often when manufacturing at high volumes and using standard connections. However, complicated or non-standard connections can be produced more cost effectively by hand. Knowing your electronics manufacturer has the tools, know-how, and flexibility to design and produce the right cable harnesses for your device is critical to the success of your product.
The specific material used in a harness largely depends on its surrounding environment. If the wires are in an environment where moisture is present, for example, the harness should be of a material that is water resistant, such as polyethylene. Cables exposed to vibration or movement that might cause abrasion should be enclosed in a harness with a heat-shrink coating to minimize the effects of chafing. Some of the most common cable harness materials include:
There are many more options. Your manufacturer should be knowledgeable about cable harness materials and guide you to the right one for your application.
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Supply chain concerns impact every aspect of electronics manufacturing, including cable harness manufacturing. Make sure your cable harness manufacturer has access to the parts you need. Verify delivery times and costs. Check to see if they have multiple sources in multiple geographies to hedge against political, social, or climate disruptions. Supply chain management is another area where a design team can add value. Design engineers can propose alternative parts that are more widely available, cost less, or are less at risk of supply chain disruptions.
Cable harness assemblies are critical to electronics manufacturing. They are the vital conduits for electrical signal and power transmission and are integral to the functionality of every electronics product, from simple transistor radios to sophisticated spacecraft. The stability and reliability of wire connections keep products operating and safe. In short, electronic products are only as good as the performance of their components and the cables that connect those components.
Wiring harnesses are everywhere, which can lead to the assumption that they’re all the same. But are wiring harnesses universal? If not, what types are available, what sets them apart, and how do you choose the right one for your device or system?
This guide explores the standardization of wire harnesses, explains why custom solutions are often necessary, and highlights how they differ from universal options.
Universal, or off-the-shelf, wiring harnesses are designed for a range of applications rather than a specific one. Their availability makes them useful for quick, often temporary, replacements or repairs.
Universal wiring harnesses typically follow a basic structure with standardized components such as long wires, labeled cables, and standard connectors, making them suitable for a wide range of applications. However, installers often need to modify them to fit specific needs. So, are wiring harnesses truly universal? In some cases, yes.
However, because engineers and system designers require flexible power and signal transmission options, harnesses must be adaptable. This makes universal harnesses most useful as a starting point or for temporary solutions.
While universal wiring harnesses have several benefits, they do feature a few drawbacks and disadvantages too. These include:
Universal wiring harnesses have found widespread use in the automotive industry. Modern Motor vehicles have wiring systems that often require maintenance and repair. Universal wiring harnesses offer plug-and-play solutions, easing vehicle upkeep for end users.
Car owners can purchase them from third-party retailers without visiting a service center. Online stores like Amazon feature a variety of wiring harnesses that suit different purposes and requirements. For instance, you can find universal cable assemblies to help connect or integrate your custom audio systems.
The modular nature of universal wiring harnesses makes these systems more manageable. So instead of being forced to replace the entire wiring of a vehicle when something goes wrong, you can just replace a single section.
Your vehicle’s engine control unit (ECU), Advanced Driver Assistance Systems (ADAS), and diagnostics are connected through a complex configuration of cables and wires. These act as the veins and arteries of your vehicle’s electronic systems, responsible for transferring digital and electrical signals.
Customized wire harnesses are cable bundles designed and built to suit these complex systems. The tailoring process makes the harnesses plug and play in the required applications, and it includes picking the most suitable materials and structures to provide maximum durability, performance, and reliability.
A universal wiring harness is the best choice if you’re rewiring your vehicle to its original factory configuration. We offer solutions tailored to various years, makes, and models. For vehicles that are mostly factory-original but include specific modifications, we recommend using a modified harness and a conversion harness to support those updates.
Contact us to discuss your requirements of automatic harness tester supplier. Our experienced sales team can help you identify the options that best suit your needs.