112:, as well as construction machinery, cable harnesses provide several advantages over loose wires and cables. For example, many aircraft, automobiles and spacecraft contain many masses of wires which would stretch over several kilometers if fully extended. By binding the many wires and cables into a cable harness, the wires and cables can be better secured against the adverse effects of vibrations, abrasions, and moisture. By constricting the wires into a non-flexing bundle, usage of space is optimized, and the risk of a
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31:
321:'s publication IPC/WHMA-A-620 for minimal requirements for cable harnesses. This publication is reviewed frequently to ensure that the standards published remain of an acceptable standard in light of potential changes to the industry or technology that may occur. The IPC/WHMA-A-620 publication has standards for a wide range of elements within a cable harness, including but not limited to
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interaction with the environment it will endure during its lifetime. This considers the operating conditions the wire harness is meant to operate under, i.e. temperature, mechanical stress, environmental and chemical wear. This component considers the protective materials wire harnesses have like corrugated tubes, braided or silica sleeves.
341:
Class 3: high performance electronic products, for products that require continued and consistent performance and where periods of inoperativeness cannot be tolerated. The environment in which these cable harnesses are used may be "uncommonly harsh." This category encompasses devices involved in life
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Once a cable harness has been produced, it is often subject to various tests to ensure its quality and functionality. A test board can be used to measure the harness' electrical capabilities. This is achieved through the input of data about a circuit which one or more cable harnesses will be part of
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Electrical engineering is the field the focuses on developing the logical, electrical and topological architecture of the wire harnesses. When designing the electrical wires that will be used one must consider the operating ratings of wires for communication protocols usually specified under the
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The design of a wire harness usually requires the effort of two main engineering disciplines that focus on different functioning requirements, mechanical engineering and electrical engineering. Mechanical engineering is the field that focuses on the physical parameters of a wire harness and its
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Another popular test method for a cable harness is a 'pull test', in which the harness is attached to a machine that pulls the harness at a constant rate. This test then measures the cable harness' strength and electrical conductivity when pulled against a minimum standard to ensure that cable
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A wire harness must also be manufactured with a terminal, defined as "a device designed to terminate a conductor that is to be affixed to a post, stud, chassis, another tongue, etc., to establish an electrical connection." Some types of terminals include ring, tongue, spade, flag, hook, blade,
329:, installation and repairs, crimping, pull-test requirements, and other operations that are critical to the production and function of cable harnesses. The standards mandated by the IPC differ based on a product's classification under one of three defined product classes. These classes are:
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The wires are first cut to the desired length, usually using a special wire-cutting machine. The wires may also be printed on by a special machine during the cutting process or on a separate machine. After this, the ends of the wires are stripped to expose the metal (or
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It is difficult to automate these processes, with major suppliers still using manual means of production, only automating portions of the process. Manual production remains more cost effective than automation, especially with small batch sizes.
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Although customer specifications take the highest priority when creating cable harnesses of a certain quality, in North
America if no such specifications are found the quality standards of a cable harness are standardized by the
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Class 2: dedicated service electronic products, where consistent and extended performance is needed, but uninterrupted service is not vital. The failure of this product would not result in significant failures or
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Class 1: general electronic products, for objects where the functionality of the final product is the major requirement. This can include objects such as toys and other items that do not serve a critical
166:), according to the design specification, to form the cable harness. After fitting any protective sleeves, conduit, or extruded yarn, the harness is either fitted directly in the vehicle or shipped.
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is decreased. Since the installer has only one harness to install (as opposed to multiple wires), installation time is decreased and the process can be easily standardized. Binding the wires into a
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Cable harnesses are usually designed according to geometric and electrical requirements. A diagram is then provided (either on paper or on a monitor) for the assembly preparation and assembly.
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173:, hand manufacture continues to be the primary method of cable harness production in general, due to the many different processes involved, such as:
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483:
468:
Kobayashi, Masakazu, Yoshiya Hirano, and
Masatake Higashi. "Optimization of assembly processes of an automobile wire harness."
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being programmed into the test board. The harness is then measured for its ability to function in the simulated circuit.
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which transmit signals or electrical power. The cables are bound together by a durable material such as
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677:
IPC Product
Assurance Task Group & WHMA Industry Technical Guidelines Committee (20 March 2002).
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IPC Product
Assurance Task Group & WHMA Industry Technical Guidelines Committee (20 March 2002).
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communication protocol's design standards developed by automotive entities like ASME, ISO or JASO.
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partial plugging of wires prefitted with terminals into connector housings (
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taping with fabric tape, in particular on branch outs from wire strands,
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361:"Cable Harnessing | Cable Harness | Cable Assembly & Assemblies"
679:"Requirements and Acceptance for Cable and Wire Harness Assemblies"
641:"Requirements and Acceptance for Cable and Wire Harness Assemblies"
509:"Helpful Guide of Wire Harness Manufacturing Terms, Tools and Tips"
244:
44:
29:
612:"Do You Know the Industry Quality Standard of Wire Assemblies?"
535:"Various Types of Wire Terminals When Building a Wire Harness"
484:"Printing wiring harnesses and disrupting and industry or two"
158:. The cables are assembled and clamped together on a special
386:"CABLE ASSEMBLY AND A WIRE HARNESS: What's the Difference?"
360:
445:"Benefits And Applications Of Automotive Wire Harnesses"
105:, a weave of extruded string, or a combination thereof.
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Pre-production can be automated in part. This affects:
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crimping terminals onto one or both sides of the wire,
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wire stripping (automated wire stripping machines),
150:) of the wires, which are fitted with any required
308:cable rather than a traditional analog multicore.
186:terminals onto wires, particularly for so-called
120:sleeve also lowers the risk of electrical fires.
421:"Everything on Wire Harnesses You Need to Know"
258:harnesses are consistently effective and safe.
342:support systems or that are used in military.
38:wiring harness installed in a component of a
8:
212:cutting individual wires (cutting machine),
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249:Pull test qualification of crimped end.
196:fastening strands with tape, clamps or
190:(more than one wire into one terminal),
470:Computer-Aided Design and Applications
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482:Bennington, Steve (6 February 2018).
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614:. Wirafe. 2018-09-24. Archived from
561:. Wirafe. 2018-10-29. Archived from
449:Miracle Electronics Devices Pvt. Ltd
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242:quick-connect, offset and flagged.
27:Bundle of electrical cables or wires
559:"How Is a Cable Harness Designed?"
323:electrostatic discharge protection
193:inserting one sleeve into another,
25:
584:"Pull-test standards and methods"
231:of wire ends (solder machine),
177:routing wires through sleeves,
1:
266:The cable harnesses used in
533:Hall, Nicole (2017-07-26).
730:
365:www.cableharnessing.co.uk
312:Industry quality standard
513:Falconer Electronics Inc
304:typically use a single
302:digital mixing consoles
169:In spite of increasing
162:, or onto a pin board (
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472:11.3 (2014): 305-311.
248:
48:
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539:Falconer Electronics
390:www.iconnsystems.com
262:In sound engineering
81:, is an assembly of
425:Wunsch Technologies
268:sound reinforcement
251:
156:connector housings
61:, also known as a
55:
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272:recording studios
108:Commonly used in
83:electrical cables
16:(Redirected from
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99:electrical tape
75:wiring assembly
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71:cable assembly
67:wiring harness
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18:Wiring harness
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59:cable harness
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690:. Retrieved
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620:. Retrieved
616:the original
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567:. Retrieved
563:the original
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542:. Retrieved
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453:. Retrieved
451:. 2017-03-28
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393:. Retrieved
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306:twisted pair
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688:. p. 6
274:are called
110:automobiles
79:wiring loom
49:Harness of
36:cable laced
622:2019-04-07
590:2019-04-06
586:. Mecmesin
569:2019-04-06
544:2019-04-06
455:2019-04-06
430:2019-04-06
395:2019-04-06
370:2019-04-06
347:References
292:between a
277:multicores
198:cable ties
171:automation
138:Production
40:Tesla coil
300:. Modern
298:stage box
229:soldering
160:workbench
152:terminals
51:car audio
708:Category
488:LinkedIn
334:purpose.
235:twisting
184:crimping
692:7 April
653:7 April
518:7 April
493:7 April
338:danger.
327:conduit
103:conduit
53:cables.
714:Cables
282:snakes
237:wires.
223:module
124:Design
91:rubber
682:(PDF)
644:(PDF)
286:looms
114:short
95:vinyl
87:wires
694:2019
655:2019
520:2019
495:2019
296:and
270:and
148:core
686:IPC
648:IPC
319:IPC
284:or
154:or
85:or
77:or
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593:.
572:.
547:.
522:.
497:.
458:.
433:.
398:.
373:.
200:.
20:)
Text is available under the Creative Commons Attribution-ShareAlike License. Additional terms may apply.
