Your Expert Wire and Cable Harness Manufacturer

Wire harness assembly has an important role in almost all electrical applications- a major reason why there is a global rise in demand for these components. Nevertheless, not many people understand the procedure involved in manufacturing these components. Well, this piece will shed the needed highlights that will help you understand every step involved in the cable and wire harness manufacturing process.

Step 1: Coming up with the Best Design

Regardless of where the wire harness is placed, its primary purposes are to ensure a streamlined, continued, and efficient flow of power and uniform transmission of information. Nonetheless, proper research and development must be outlined for this to be possible in electronic products. This means that the designing aspects have to feature the necessary components and specifications to tackle the day-to-day electrical problems before being implemented.

However, the difficult part associated with designing is making sure there is a clearly defined custom approach to the cable assembling parts for maximum productivity. This step also involves coming up with the right outline that will be followed throughout the production period.

Step 2: Creation of a Prototype

Cable harness assembly wire prototype creation helps the manufacturer to have a better understanding of the end product. At this stage, the prototyped harness goes through the necessary evaluation and tests based on its uses. Once the prototype harness passes the evaluation, the next step, which is production, is then initiated. The importance of this step is to confirm if the end product will be able to provide optimal performance.

Step3: Manufacturing and Assembling 

This step involves putting into action the earlier steps starting from the design’s specifications. However, high-quality measures with zero or almost zero chances of errors must be adhered to. As much as automation also plays a vital role in this step, it is important to note that custom wire harness production depends highly on manual assembly. This is regardless of the existing technological advancement and its high impact in every global manufacturing sector.

Incorporating automating technology into the fabrication process is a good option. Considering the complex processes involved in the cable assembly. However, due to different production reasons, handmade production of wire harnesses remains the best choice even in this current error. This is as a result of the complex and time-sapping procedures involved in finishing the manufacturing process.

Manual application during wire harness assembly therefore includes:

• Applying tape in different locations and in different amounts
• Crimping the terminals to the wires, which will at times require several crimping procedures
• Inserting the sleeves into each other
• Tightening the clamps and strands, and cable ties.

Another vital reason for the manual production of the custom cable assembly is customization specifications. Each wire harness has to be customized to meet its specific application.

They are supposed to resolve problems in various manufacturing applications and also come up with both geometric and electrical solutions to the entire process. Geometrically custom cable assembly is specifically designed to fit a space within a much greater electrical wiring and components network.

Therefore, production has to guarantee that the customized cable assembly offers the required protection during application. This includes both internal and external harm arising from defects caused by moisture, crossing wires, and even chemicals.

The production step will therefore include:

1. Wire Cutting 

The wires have to be appropriately cut to the recommended lengths to build the right and most efficient custom wire harness. This is done using a wire cutting machine.

2. Stripping 

Stripping is an important step that usually follows wire cutting. It involves stripping the ends of the wires so that the cores can be visible. This step aims at enabling the attachment of the connector housing or terminals.

3. Assembly

Finally, the wires will then be placed into the harness through a workbench or the assembly board. This is to ensure they meet all the design specs.

4. Testing the End Product

Once the production comes to a halt, all the wire harnesses will have to undergo a process known as electrical safety testing. This exposes the cable assembly to all specifications that it may fall subject to in the real-world application. This final step is very important in confirming that the product has the ability to offer 100% reliability during application regardless of the environment.

Finally,

Wire harness production is a process that requires better understanding. From the design, assembling, drawing board to finished cable assemblies products, all this requires the implementation of appropriate steps.

Remember, each customized cable assembly has to meet a particular purpose to integrate with the application system. This makes wire assemblies indispensable in the present-day world.

Many factors go to the designing of even the most straightforward cable assembly. The wire and harness selection process is one of the factors. The type of cable assembly wire used in the harness will determine how effective the wire harness will be during application. This makes wire selection a very critical component in a cable assembly’s design.

The cable assembly wire has the ability to affect the functionality, safety, and efficiency of the assembly. Nevertheless, choosing the right assembly wire type has never been an easy task considering the many options that do exist. This is why this piece provides answers to different questions regarding the selection of a cable assembly wire.

What should I consider in terms of wire size?

There are two approaches to the custom cable assembly wire size. This includes the length and gauge. With the gauge, features such as the load and current capacity will have a major role in the wire selection. Keep in mind this is measured in amps or amperage. Also, keep in mind that the wire gauge is inversely proportional to the required number of amps that run through the wire harness.

The length also determines the wire to be used. With no available wire that can be considered as the perfect conductor, you have to understand choosing a long wire increase the possibility of more voltage loss. This will step up the amperage volume, which in turn pumps up more amps. This ensures the appropriate electricity is distributed.

How flexible the wire has to be?

Numerous wire assembly types feature various flexibility degrees as outlined below:

• Strong core wires: these wires carry zero flexible degrees within lower gauges. However, they tend to become more flexible within higher gauges.
• Stranded-coarsely wires: these wires feature a more flexible degree. This means they are able to uphold a given shape
• Fine stranded wires: these wires offer highly flexible degrees but cannot hold a given shape.

What wire is the best for insulation cable assemblies?

With wire insulation, the wire harness working area will have a significant impact in terms of voltage, coating, and abrasion resistance, among other factors, as indicated below:

• Voltage; voltage determines the wire choice in that, a high voltage level necessitates a thick insulation wire. This is to ensure there is efficient minimization of risks associated with shocks and shorts.
• Coating: A coated wire simplifies the assembly’s connection.
• Environmental consideration: harsh environmental conditions, including temperature, UV lights, and chemical presence, can impact the performance of a wire within a cable assembly.
• Regulations and requirements. The requirements and rules governing the wire harness production will have a huge impact on the choice of wire.

Does the wire color have significant importance to the assembly?

Colored wires within an electrical harness can have significant importance to the user. This also applies to anyone who may wish to service the wire harness. You, therefore, have to understand the purpose of the cable assembly wire before making a choice. Manufacturers will implement the application of differently colored wires in a cable assembly so as to make it simple for users to identify the neutral and ground wires.

Which wire serves better in a cable assembly between copper and aluminum wires?

Copper is always the best option due to its conductive nature. However, for many people, copper can also be an expensive option. For long distance wire harness uses, aluminum wires are the best. Aluminum wires are acceptably good conductors with thicker gauges. They are also an affordable option. Here the choice will highly depend on the wire harness application.

Finally

In short, the type of assembly wire to use in your cable assembly will depend on the industrial application of your project. For automobile cable assembly applications, it will be wise to go for a wire option that has the ability to withstand extreme environments.

To get the most out of a cable assembly system you have to make sure you come up with the right connector. This is simply because the right connector will ensure the cabling system is in a position to offer the perfect application within a given environment. So what is a connector?? Read on to have a better understanding.

A connector refers to a component that is usually attached to the end of a cable so that the cable can easily plug into an electrical system or plug. They exist as either male or female connectors. The male connector usually has single or more disclosed pins. Female connectors on the other hand feature holes for perfect male connector insertions.

With this in mind here are some of the most commonly used connectors for cable assemblies:

• Board to board connector
• Wire to board connector
• wire to wire cable connector

Board-to-board cable connectors

Board to board connector is mostly used in connecting PCBs without cables. These connectors, therefore, play an important role by saving space on the cables making them perfect for systems that feature limited space. PCBs connect by applying the connectors in a vertical or parallel configuration.

Connectors that are able to join two PCBs through a stacking configuration are called Mezzanine connectors. However, this term is at times used in describing perpendicular PCB arrangements commonly seen in motherboard-daughterboard arrangements where the main focus is usually on the parallel arrangement.

When choosing a mezzanine connector there is some aspects and specification that you just have to consider. This includes the mechanical necessity like the stack’s height, tolerance, separability, limitations such as brackets and standoffs. With separability, you have to outline factors like whether the connector is permanent or separable and the total number of mating cycles required by the connectors during its lifetime among other factors.

Some of the common examples of Board board cable connectors include:

• LEL Board-to-board connector: this board-to-board connector features a 1,2mm mating height which makes it possible for the connectors to provide important features within a cable assembly such as space-saving options and simple connections between a PC boar. It also has a mechanism that helps in the prevention of wrong insertions.
• DID board-to-board connector feature a 2.54mm pitch. It was originally designed for TV applications. This connector has a secure locking system that helps in holding the house and improves the PC board resistance to vibrations and shocks

Wire-to-board cable connectors

A Wire to board connector is used in connecting wire/cable to the PCB. It has a similar connection to that of a wire-to-wire connection. The board connection is mostly soldered two-piece or press-in connectors. However, card edge types are still being used. While these connectors have lots of applications, they are mostly used in cable assemblies to maximize the advantage of IDC benefits.

Examples of wire-to-board cable connectors include:

• RAD connector: this is a hybrid wire to board connector that is perfect for automobile radio applications.
• JWPF connector: this connector is mainly designed for smaller applications that require water ingress resistance.

Wire-to-wire cable connectors

Wire-to-wire connectors as the name indicates are used in connecting two wires. One of the connectors will be permanently connected to a wire while the other part of the connector forms separable interfaces. To achieve the permanent connection you either apply crimping or insulation displacement contacts.

With IDC, the connection is achieved through the insertion of insulated wires into the sharpened metal beam’s slot. The edges of a beam will cut through the insulation thus making a rigid contact within the two components which is the wire and beam.

However, in a situation where there is a discrete wire assembly, then a crimping process will have to be applied. Nevertheless, in multi-conductor cable termination, IDC will simply work the magic. This is simply due to the many advantages that come with IDC in regards to wire mass termination and wire handling.

Wire-to-wire connector features a wider option when it comes to housing geometrics. This includes circular and rectangular housing made from different polymer varieties and metal shells majorly for military uses.

Some of the examples of wire-to wire connectors include:

• PicoBlade connector; Offers a balance between size, performance and affordability.
• Micro-Fit Connector: Features premium housing specifications that help in reducing terminal back-outs and operator fatigue during the assembly.

Twisted-Pair Cable connector

This connector is mainly applied in both the unshielded and also screened twisted connector pairs. Their design features a modular jack and plugs with an asymmetric shape that can be keyed. This simply means that a twisted pair connector comes with a special pin configuration.

Both two types of twisted pair cable connectors can be used with IDCs connectors when it comes to the connection of patch panels and wall plates.  Nevertheless, for the termination of these connectors, the cable will not necessarily be stripped like in screw-down connections. Instated the in-between connectors facing the piercing blades into plastic insulation are forced to make the connectors contact.

Finally

Every connector type has an important role in its application. It is therefore important to have a better understanding of your application requirements before settling on a cable connector. This will help you choose whether to settle for a custom connector or an industry-produced connector

Connectors have a vital role in electrical applications. However, you have to ensure you choose the best connector for your wire assembly for maximum efficiency. As much as this can seem like an easy task, the truth is that the chances of choosing the wrong connector are very high without the proper guidelines.

With over a million connectors to choose from, here are five central questions to consider before deciding on which cable assembly connector to use.

What is the electrical requirement for the connector? 

A good start for narrowing down your search has to be the electrical requirements of the connector. This includes the voltage, the number of signals, currents, and the frequency being carried. Here the signals could either be power, digital, analog, or all of them. Also, keep in mind that the analog and digital signals can either be low or high frequency. The signal’s precise combination will certainly have an effect on the connector type, pin-out, and wiring assembly.

Also, keep in mind that other signal combinations might not be compatible with the same wire harness connector inclusion. If you are therefore dealing with electrical signals only or surgical equipment that requires gas or fluid lines, then a custom connector will be perfect for your cable assembly.

Are size and space a constraint?

New technological trends involve size reduction in almost all electric machines sectors. Most machines that previously occupied lots of space have now been reduced to portable machines. This also affects the size, weight, and space available for connectors. This has also led to an increase in the connector’s ability to withstand increased mating and un-mating frequency.

If this is the case with your project, you have to make sure you go for a wire harness connector that can match your project application.

Will the connector operate under extreme environments?

Most available wire assembly connector systems are designed to handle extreme industrial and mechanical applications. This includes shocks or vibrations. However, connectors designed to handle these situations are normally equipped with unique features like threaded coupling and strain relief. This helps the connector not to vibrate loosely, while strain relief supports the connector wire harness.

Such connectors usually indicate their specification. This means you can easily tell if the selected connector can withstand harsh environments.

Are there any obligatory industry requirements?

Most of the industries have imposed standards that OEMs have to meet. Even though the requirements might affect the connectors directly, they will apply to the machine that the connector will be part of. FDA is responsible for setting standards for medical machines, while SAE handles automotive standards, particularly in hybrid cars. Not forgetting MIL standards on defense-related machines.

These standards are not only limited to covering reliability and performance but even the manufacturing standards and stringent qualifications. Therefore, make sure you abide by all the necessary standards within your industry.

What type of termination is required?

Terminations have a vital role in joining a socket or wire-to-wire connector pin to the conductor. This conductor can either be PCB, wire, or anything else. Here, it would be best if you kept in mind the available terminal types: crimped connections, press-fit, wire wrap, or soldered connections. Every terminal has its unique feature.

Crimped connections are usually easy to work with and repair in a field. However, the termination choice will highly depend on application and design in general.

Finally,

Every custom connector application features different uniqueness, design constraints, and cost factors. Therefore, you should use the above questions as a guideline to narrow down your many options.

Connectors are devices responsible for connecting or completing electrical circuits and signals. Most of these connectors can either be temporary or removable. However, some are permanent. The primary purpose of connectors is to ensure that all electrical products become more accessible to assembly and also manufacture. At the same time, ensure efficient signal and current transition.

They are also responsible for easing circuit repairs and allowing resilience in modification and design. They are mainly used on circuits for industrial machines, communications, PCs, and consumer electronics.

Well, there are different types of connectors, all based on their applications. However, in this piece, we will be outlining the significant differences between an original connector and an equivalent connector, also known as replacement connectors.

So what is an original connector?

Original connector simply refers to big-name connectors. These are connectors produced by well-established manufacturers such as Molex, JAE, JST, Lumberg, and TE. All these are companies that have been in this industry for so many years. They are also famous for their high-quality connector production and continued inventiveness.

What is an equivalent connector?

Equivalent connector, commonly known as replacement connector or compatible connector, mostly refers to connectors manufactured by local producers. However, this does not mean that a replacement connector is of poor quality. All the specifications of these connectors, including pitch, appearance temperature, and material, are similar or even better than those of an original connector.

The main difference lies with the fact that a locally manufactured cross connector does not have that famous tag that comes with an original connector. However, they also can become original connectors in the future.

Why is an equivalent connector the most preferred choice by many users?

Even though a Chinese equivalent connector might not have high standards like that of an original connector, they are still the most preferred option by many users in the market. All these are attributed to the fact that these connectors feature a price-friendly tag.

Many people, therefore, prefer an alternate connector due to the following reasons:

• These connectors come at an affordable price
• Customized according to your specifications
• Features regular updates
• Quick delivery
• End users do not have to use the producers brand
• Increases design flexibility
• Easy to use

The major setback with an alternate connector is its low lifespan.

Cross connectors application includes in small home appliances such as electric fans, electric iron, and kettle, just to mention a few.

Some of the local manufacturers of alternate connectors in China include ECOCABLES, LHE, JVT, HR, and HRB.

Important to note is that some equivalent connector quality can be better than original connectors depending on the production process and the skills put in place.

Why use original connectors?

Original connectors are mostly used since many people believe and trust the products of well-established companies with big names. However, these connectors also feature high-quality production through high-tech machines, making them stand out.

Original connectors, therefore, stand out due to the following reasons:

• Longer life span of up to 10 years
• Larger markets, including overseas markets
• High-quality products
• Ability to thrive even in harsh environment
• Lower maintenance
• Minimal power loss

The main disadvantage of original connectors lies with their price. These connectors are mostly expensive.

Original connector is primarily used in the application of home appliances, medical equipment, smartphones, camera, elevators, and mostly in office machines, including computers.

Finally,

The truth is that both the original connector and equivalent connector application will depend highly on the user. Both of these connectors have the ability to offer nothing but exceptional services. It, therefore, boils down to you and your project.

However, essential to keep in mind before making a decision is the delivery time, the recommended certifications, quality, and your project’s budget. With these aspects in mind, you won’t have a problem choosing between equivalent or original connectors.

A wire harness cable assembly is crucial in commercial, consumer, and industrial products. Users rely on it to offer reliable power sources in different applications, including power tools and high take installations such as security systems. However, despite the best mechanism being put in place to identify and rectify any cable assembly errors during production, there is always a small percentage of errors that could have been missed out. This is the primary reason why testing these components before they can be used for different purposes is essential. The testing process helps troubleshoot any error and verifies that all components assembled are working correctly.

To ensure that there is no possibility of errors in your cable assembly during the application, it is wise to at least carry out a few assessments. The tests performed should be able to cover the mechanical, electrical, environmental, and signal integrity capabilities of the harness. To help you better understand how to check if your wire harness is in its best form, this piece will cover in detail the necessary tests to undertake.

Mechanical Tests

Mechanical tests help in assessing the mechanical features of the wire harness. The assessment, therefore, confirms if the cable assembly is in a position to meet the task at hand requirements. With mechanical testing, you will have an easy time identifying errors associated with the cable assembly’s file flexibility, elongation, and tensile strength, not forgetting the harness resistance to crush and impact.

However, as much as some of these errors are easily identifiable through mechanical testing, intermittent errors can be challenging to find compared to solid errors. This is because they don’t occur in a consistent manner. The custom cable assembly must be in a specific position or under a certain temperature for these errors to manifest. Some of the most common causes of intermittent errors include:

• Badly placed specifications: this is where a value is set to only allow the cable to pass the intermittent assessment. However, readjusting different specification values will help in eliminating this error.
• Cold solder joints: Moving a contact before the solder is set will make the solder weak, leading to intermittent errors.
• Damaged housing/ insulation: damaged wires from the connector’s housing will cause intermittent shorts.
• Dirty contacts: contacts that have dirty residues or other contaminations can lead to intermittent errors.
• Bad interface; Worn out cable interfaces of contacts will make it almost impossible to identify intermittent errors with the harness.

Environmental Tests

Environmental tests will help you determine if the harness has what it takes to flourish in different environments. To withstand the harshest environments, including high temperature and humidity regions, the wire harness must therefore have the appropriate capabilities and features with zero errors. Wire harnesses that can function best under the applied environmental conditions are considered the best based on your application.

Visual Tests

Visual assessment simply means identifying errors that are openly visible by the eyes. For a practical visual test, you have to make sure all the harness components are perfectly fitted and are in the best condition. Here you have to be on the lookout for things like:

• The cables/wires gauge and placement. You should also check for any damage to these wires.
• The terminals/ connectors. Here you have to ensure the appropriate connector types or terminals have been used in the custom wire harness.
• The labeling. Proper labeling helps when it comes to placement and accuracy.

Performing a test on the harness dimension also plays a vital role in determining if your cable assembly has met the right specifications.

Signal Integrity Tests 

Signal integrity testing helps in checking several errors within the wire harness, with the major error being the harness signal strength. It also checks for standard errors like crosstalk malfunctions. In this assessment, you can also determine if incorporating different components like filters and splices can help maintain or improve your cable assembly signal strength.

Final Thoughts 

Remember, just because the cable underwent production testing does not mean it is unquestionably a good cable. There is a lot that the manufacturer could have missed. Therefore, carrying out the above test will certainly help you have an explicit confirmation that you are dealing with a cable assembly that is 100% perfect

wiring harness loom has a significant role in many applications. However, designing and manufacturing this assembly is not as cheap as many people tend to think. Therefore, a custom wire harness assembly production can have a significant impact on your financial status. While quality has to remain a priority, you can consistently implement different approaches that can help you save a little bit, as outlined in this piece.

However, before you look at the loom wiring harnesse cost-saving options, two vital aspects must be reviewed. This is to ensure that as much as you are trying to develop a cost-saving option for your cable assy, you must also adhere to all the rules governing affordable wire harness manufacturing.

1. Bill of material catalog: This is a list that highlights all the materials required to produce a cable loom. Taking a look at the list can be an excellent place to start your venture as far as cost-saving cable assembly is concerned. However, you must also ensure that you abide by the CMs rules and regulations. Also, pls ensure you follow OEM material rules.
2. Specifications catalog: This catalog will help you have an easy time inspecting all the materials and components of your custom wiring loom. It will also help you identify areas where you offer cost-saving options. This must, however, be done by putting into consideration the quality of your wiring looms and harnesses.

Having a clear understanding of these two catalogs or documents will help you have an easy time considering these cable assembly cost-saving options.

Go for the suitable materials

Raw materials have an essential role in the manufacture of cable assemblies. Nevertheless, for you to save on this process, you must order the materials needed in bulks. This should be done after considering the right raw material combination beforehand.

Pick the right connectors

Cable assembly production requires different connector types. Nonetheless, the approach used in assembling these connectors into the assembly will highly depend on the application at hand. The method used in the assembly of the connector, whether it’s soldering or crimping, will impact the production cost. Better understandings of the transmission features of the cable assembly will therefore allow you to pick the appropriate connectors and, in the end, save cost.

The cable conductors

The rule governing conductors is that the smaller they are, the less costly they become. Nevertheless, you have to be keen here. The small conductor’s size should not affect the wire harness in the future or limit the functionality of your new wiring harness.

Make sure you go for an affordable conductor that has the ability to meet your assembly’s requirements.

Go for cost-saving wire options 

Most manufacturers usually spend a lot on costly wires that are not even required during the wire harness assembly. Wires are usually selected after considering a few aspects. First, you have to make sure you go for a wiring loom wire that meets the right certifications. Having ensured that the wire meets the right certifications on the applied cable assembly application, it becomes easier to pick the right cost-saving wires.

Settle on proper testing 

Cable assemblies with lots of applications or large workloads should undergo the right testing. Partial and visual tests are just not enough. Undertaking detailed tests will help you identify any errors that might tend to arise in the future. This, on the other hand, eliminates the possibility of downstream repairs and replacement that can cost more money.

Go for experience 

When looking for a manufacturer to handle the production of your cable assembly, it is important to go for someone with the right experience. Such a professional will offer reliable direction, especially when it comes to materials. Materials play a significant role in your saving endeavor. Therefore a skilled professional will help find affordable but dependable material substitutes.

A dedicated team with the ability to think cohesively plays a vital role in achieving your goals. Therefore, a manufacturer who comprehends your organization’s requirements will be in a better position to warn you against unnecessary materials. Thus, going for custom cable assembly manufacturers ensures both time and cost-efficiency.

Finally,

There are a lot of ways you can use to save on cost during a custom wire harness production. However, your saving intention should not affect the efficiency of your wire harness. This can end up costing you even more in the future.