Wire Harness Inspection

Wire harness operates similarly to the circulatory system of human beings. They transfer messages and deliver energy while collecting and distributing data. The data helps in describing the external environment of the system. However, wiring harnesses and cable assemblies are some of the most neglected and overlooked components in almost every design despite being vital when it comes to the overall performance of an electrical gadget.

Wire harness refers to an assembly or combination of wires that transmit power and signal throughout an appliance. In 1980, wiring safety became a significant issue due to increased accidents, especially in the airplane industry. All this was attributed to the airplane’s electrical wiring system’s degrading aspects. This further pushed a deeper investigation into the wiring quality and assembly being offered by different companies.

The conclusion was that the need for better regulation and wire harness inspection was a must if they were to ensure reliable and efficient application of wire harnesses. Before digging deeper into wiring harness inspection, let have a clear understanding of the leading causes of wire harness failures.

What are some of the Common Causes of Wiring Harnesses Failing?

Wire Harness Inspection

Even the slightest wire harness issue can have a huge impact on its application. There are various reasons why degradation occurs. Lack of proper maintenance is one of the main issues – this means that proper cable assembly inspection must be outlined and conducted by professionals.

The environment under which the wire harness operates can affect its performance. It’s therefore essential to ensure that each wire harness is designed with the ability to meet the environmental condition it’s supposed to operate under.

What is inspected in a Wiring Harness?

The wiring harness features different conducting wires within an insulated covering. This covering is manufactured using hands by very skilled professionals and technicians. However, a routine wire harness inspection is required, including both the internal and external components of the wire harness.

During the wiring harness inspection, some of the aspects to look out for include:

  • Corrosion
  • Dirty connections
  • Loose terminal connections
  • Poor electrical bonds
  • Loose or broken conduit and wiring

It’s vital to keep in mind that a visual wire harness inspection is never enough to determine if a wire harness is safe or not. Therefore always ensure you also remove the deconstructed components for full inspections. Combined wires can easily conceal different issues that will be hard to see without removing the whole wire harness system. Here, it’s also vital to use different machines that help provide a clear and visible wire harness inspection.

What are the Benefits of a Wire Harness Inspection?

Wire Harness Inspection

Wire harness inspection offers a wide range of benefits to both the end-user and the manufacturer. The inspection helps ensure that users can purchase a wire harness that has met the right requirements and standards. The inspection also aids in identifying any issue that the wire harness may have, which can affect the system’s overall functionality. To the wire harness manufacturer, the cable assembly inspection helps ensure they can produce a wire harness that offers optimum functionality upon its application.


Wire harness inspection has to be conducted to ascertain the reliability of a wiring harness system. It’s therefore essential to ensure the right maintenance and inspections are perfectly outlined for better and reliable services.

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