To those of us who work as cable assembly manufacturers every day here at Technical Cable Applications, as soon as we learn about the application a client is needing, we will typically know whether a wire harness will do the job, and when a more robust cable assembly is required. However for just about anyone else who doesn&#;t work with cables every day, it&#;s likely that the terms &#;wire&#; and &#;cable&#; will seem somewhat interchangeable. It&#;s also even more likely that your average consumer wouldn&#;t know the difference between a harness and an assembly as those also sound very similar, and again wire versus cable sounds like you&#;re comparing the same thing. This will be a quick refresher on the difference between a wire harness and a cable assembly, and when one or the other is most likely to be used.
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Wire Harness
Wire harnesses are the most basic way to configure any product or project that needs a couple or more wires strung together to connect one item to another. As long as the wires are in a safe place without extreme temperatures, pressure, or other physical danger, oftentimes this simple configuration of attaching a few wires together to ensure that everything will get the power or data transfer needed is more than sufficient. Wire harnesses are extremely cost efficient and will more than suffice for many indoor applications, or applications where the wires will be protected by a product&#;s pre-existing external shell or casing, i.e. computer servers or refrigerators.
Cable Assembly
The primary difference between a wire harness and a cable assembly is that a cable assembly will not have single exposed wires, and will always have multiple wires braided together and covered in some sort of protective sheath or coat. Cable assemblies are most important to use when there is no additional protection for the wires from the elements or when the connection has to hang rather than being precisely placed and mounted. This is because the protective sheath will ensure that the cables are protected from damage even if they are visible outside the product or machinery they are powering. Cable assemblies can be encased in all sorts of different types of protective materials for many different applications, so whether your cables need to continue working in harsh outdoor environments, or extremely hot factory/industrial conditions, there is a method and a material for your needs that will protect your cables and keep them working. Some industries use cable assemblies more frequently as well due to their general durability and the fact that protective sheaths can also prevent data loss, which is excellent for the military and medical fields who need both high durability and fast data transfer in emergency scenarios.
Hopefully this guide is helpful for anyone who is not familiar with the nuances between cables and wires. If you&#;d like to learn more, WHMA.org has an excellent guide they&#;ve published as well that is more in-depth than what we wrote here. Meanwhile if you are in need of a manufacturer for your bulk cable assembly or wire harness needs, please give us a call or send your cable drawing to us via our contact form so we can get started.
The wiring harness market is growing quickly, especially in North America. As a business looking for a custom wire harness system, accuracy is the primary goal. For this, every little detail count. Choosing the right wire harness manufacturers is more important than you think. It is crucial to ensure the safety and durability of the system.
Unlike other companies, wire harnessing manufacturers need to follow these standards. If you choose a manufacturer without considering all the factors, it might give you a poor result. Otherwise, it can compromise the safety of both the product and the user.
Let&#;s briefly examine what to remember while choosing the right wire harness manufacturer.
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for more details.The manufacturer must conduct rigorous testing on the cables and wire harness assemblies. That is necessary for every order. Performing both visual and electrical inspections can prevent any errors in the future. That will also ensure greater accuracy of the system.
Ensure that the company has the experience and ability to test before ordering. They should also have the necessary testing equipment for physical and electrical examination.
Here, the company can make use of pre-programmed test boards. They can program these test boards with the electrical requirements of the project.
It will enable them to test the wire harness parts in groups or components. That will contribute significantly to creating a safer and more reliable final product.
The company should also show the test reports of all the electronic wire harnesses made by them.
These are some of the tests manufacturers use:
Hipot Test/high potential test for checking isolation. Alternatively known as Dielectric Withstand Test, it checks for excellent isolation. It ensures that there is no flow of current from one point to another. This high-voltage test can detect crushed insulation, braided shielding, and stray wire strands.
Contrary to the Hipot test, the Continuity Test ensures the current flow from one point to another. Also, they ensure that each wire hooks up or connects, corresponding to its original design.
Before you order, make sure the company has a stringent quality control system in place. The manufacturer should only offer products of superior quality. Furthermore, make sure to check the following in a wiring harness:
The crimp should never break the insulation. Instead, it should completely wrap around and support the insulation. Furthermore, it should not expose an opening bigger than 45 degrees.
The most appropriate wire gauge for your assemblies depends on the quality of the wire. These qualities include the length and resistance of the cable. Moreover, identifying the right measure for your wiring is a complicated process.
That will depend on the purpose and nuances of your final product. Interestingly, the bigger the size of the wire, the smaller the gauge becomes.
Choosing a larger gauge has its merits, for it significantly lowers energy costs. However, this means that your product will be more expensive.
It is due to the considerable amount of conductor material you need for its build. Besides, this might only be useful up to a certain point.
On the same note, opting for tiny conductors might also make the assembly costlier. It is due to its intricate extrusion process. The right choice is to find the perfect gauge for your wiring harness system.
Also, make sure to carry out the following:
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Insulation should not have punctures or tabs penetrating the cables. Also, check if the insulation reveals wires &#; a sure sign of damage. Broken insulation is a grave matter as it can cause severe safety hazards.
Moreover, as it is tough to detect damaged wires beneath insulation, you need to be extra careful. Check carefully for any scrapes, nicks, or other such damages in the cable.
The shape and size of the wire terminal will depend on the size of the screw and wire. Additionally, determine whether you need an insulated or non-insulated wire terminal for your project.
Insulation acts as a non-conductor by providing a layer of added protection. It protects the wire from elements such as water, heat, and cold.
If you do not need added protection, you can go for a non-insulated terminal &#; a cheaper option.
You can choose from various types of terminals. For instance, you can go for a ring, hook, fork, and bullet.
Insulated terminals come in both partially insulated and fully insulated types. Somewhat insulated terminals are generally used on ring and fork terminals. They prevent wires from shorting or crossing.
Meanwhile, fully covered terminals on quick connect/disconnect terminals avoid contact between wires. However, for non-insulated terminals soldering or crimping them in place is necessary.
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for more details.The wires are color-coded for better organization and easy identification. The color codes used in wire harness manufacturing is as follows:
Ensure the company is capable of creating a reliable, high-quality wire harness assembly. The product should suit your project&#;s specific electrical requirements perfectly.
That includes the size and thickness of the wire and materials that you need. Design requirements, such as insulation, are also necessary.
In most companies, wire harness manufacturing is a manual process. It is because manual production is more cost-effective than automation in this case.
Manufacturers cater to customized orders that require highly specialized products in small quantities. Therefore, manufacturing by hand is the best option.
They should also test and retest these customized harnesses to ensure their reliability.
Straps secure both sides of the harness at the points where the wiring splits into two. There are different kinds of straps available such as ground strap and bonding strap. Bonding straps create an electrical flow between two points. Meanwhile, ground straps provide a ground potential to ensure protection from electrostatic discharge. The latter will protect the device from short-circuiting.
Make sure the company has a safety certification from UL, CSA International, or ETL. UL tests and certifies the safety and function of wires and cables based on rigid standards. They offer the highest standards and best practices for the wire harnessing industry. These certifications mean that the company complies with international and industry-wide standards. They also have to upgrade their training processes regularly according to these regulations.
Sometimes the customer may not have specific requirements. In that case, the manufacturers generally follow the standardized IPC A-620 certification. It is the widely accepted industry standard for wire harness installation and fabrication.
If you carefully consider all the above factors, you can ensure a safe and smart purchase for your project. Selecting the right manufacturer for wiring harnesses and cable assemblies will surely save you money and time. But it is also crucial for the most important factor &#; your safety. Invest some time to align your needs with the wire harness manufacturer.
Talk to us to help you. Our customizable wire harness options will suit your needs better. Plus, you will love the accurate custom wire harnessing system for sure.
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