Comprised of a collection of wires, cables and cable assemblies bundled together with ties, tubing or tape, the purpose of a wiring harness is to simplify the installation of components and equipment in an electrical or electronic assembly. A custom wiring harness is designed around a specific assembly configuration, with wire and cable lengths optimized for ease of installation and to prevent wiring from interfering with device assembly or functionality. Wires are specified to meet performance requirements of both the individual device and the full assembly, and assembly into a wiring harness offers a degree of protection for the cabling itself. Another advantage of a wiring harness from a manufacturing perspective is that the harness may be ordered, installed and inventoried as a single part number.
Harness Components
The various wires and cables included in a harness may be simple jumper or hookup wires with single end terminations, or they may be complex wire bundles or cables which are supplied by the component manufacturer or specified to meet device requirements or industry-specific criteria. Some cables may require fabrication or additional customization before they can be installed in the harness, and shielding may be required for protection against electromagnetic interference.
Wiring Harness Assembly
To build a custom wiring harness, the individual interconnecting wires, cables and connectors must be identified for each component. Routing paths are then measured to determine the optimum cable lengths. Once wires and cables are cut to size and connectors applied, they are positioned into the wire paths for assembly and then bundled together into a rubber or plastic sheath or secured with cable ties. Mounting hardware may also be incorporated into the harness for ease of attachment during assembly.
Wiring Harness Features
In addition to custom cable lengths, a custom wiring harness will typically have multiple branches, and harnesses may be assembled with built-in strain relief. In some cases, circuit boards or various active or passive components are integrated into the wiring harness. In addition, smart harness boards can be incorporated for simultaneous build and test during fabrication.
Wiring harnesses are an important component in any electronic system. The quality of wiring and connections can impact overall system performance of any device, so it is important to work with an experienced wiring harness manufacturer. Sensitive electronics and circuitry can suffer damage due to improper connectivity, which is yet another reason to work with a well-qualified supplier to develop your custom wiring harness.
A custom wiring harness can greatly simplify the assembly process where electrical connectivity is required. The use of high quality cables and connectors in a custom wiring harness can help to maintain optimum system performance.