Streamlining the Wiring Harness Building Process

Building Wiring Harness

Building a wiring harness is an important process in the manufacturing of automobiles, construction machinery and white goods such as washers, dryers and refrigerators. It reduces installation time by binding many wires and cables into a single unit.

The first step is to create a wiring diagram. Next, you must cut the wires to length using a wire-cutting machine and strip them with a wire stripper.

Wires

A wiring harness consists of wires which are connected to the terminals and connectors. A harness is used for a wide range of applications in aerospace, automotive, medicine, telecommunications and commercial buildings. Wires are available in different gauges, which determine how much current they can carry. Choose a suitable wire for your application, and choose the right length to prevent stress on the connections.

Consider adding insulators such as wraps and ties to prevent the wires from tangling together. You may also add wire tapes, looms and sleeves for additional strain relief. Ensure that the end of each wire is labelled to help you identify them later.

Terminations are the connectors that connect conductors and protect them from environmental conditions, such as abrasion. They include ring terminals, spade terminals and hook terminals. They are available in insulated and non-insulated versions. You should also use heat shrink tubing to cover any exposed ends of the terminals.

Connectors

The connectors in a wiring harness are the electro-mechanical devices that relay an electronic signal from one circuit to another. There are many different types of connectors, each designed to suit a particular purpose. They range in size, shape and material. Some are insulated, while others are not. Insulation protects the connector from moisture and extreme temperatures.

There are also a variety of terminals available. These include ring, spade, flag, hook, blade and quick-connect. These are used to connect wires to a fixed post, stud or chassis to establish an electrical connection.

The right connectors are essential for a wiring harness to function correctly and efficiently. They create an electrical circuit and help protect the wires from abrasions, moisture and electromagnetic interference (EMI). Additionally, they help reduce the risk of fire. Choose a connector with a high durability rating. It should also be suitable for the environment in which it will be used. For example, if the wiring harness will be exposed to high temperatures, select a wire with a higher temperature rating.

Terminations

When a wire harness is assembled, it is typically bound together with a variety of options including wire ties, lacing, sleeves, tape conduit or a combination. These options make it easier to organize the wires and help streamline the installation process. The ends of each wire are usually terminated with terminals that fit into keyed housings for error proofing.

The connectors used on a wire harness will depend on the application and can include either a crimp or soldered connection. The choice will be determined by the operating temperature, harshness of the environment, and exposure to chemicals & fluids. Secondary harness protection, also known as sleeving, is often added to protect against abrasion and other environmental hazards. It is important to use the proper material for insulation and sheathing, as this will impact the overall performance of the assembly. It is also a good idea to choose the correct termination method for the connectors. Conventional termination processes place a first and second terminal station on a linear production path that is the same as the wire feedpath.

Tools

During the building process, it is important to have the proper tools for the job. For example, a basic pliers-style crimp tool will work for a variety of wires and connectors. Additionally, it’s critical to use the right sized tool for each termination, as this ensures proper connection and avoids any damage to the wires or terminals.

Another essential tool is a soldering iron, which can be used to make the crimp connections. The iron can also be used to splice wires together. Additionally, you’ll need a tool for stripping the ends of your wires and a wire cutter.

For a variety of Wiring Harness Assembly products, TE Connectivity serves entrepreneurs and engineers with an impressive arsenal of innovative products. They provide wires and terminals for industrial, automotive, medical and home electronics applications. Their extensive inventory list includes electrical connectors and other components from 750 industry-leading manufacturers. They offer low order minimums and competitive pricing.

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