The demand for wire harnesses continues to grow and with it we need to understand the manufacturing process of this critical component in detail. Before we offer a step-by-step guide to the manufacturing process, let us look at what wire harness assemblies are and what are the benefits of their use.
Simply put wire harness assemblies are the bundled processed wires with a protective sheath. Harnesses are important as they organize wires for easy implementation. They are different from cable assemblies in that cable assemblies bind multiple covered wires with a covering to provide protection in harsh environments. Make the right choice between cable assemblies and wire harness assemblies.
Wire Harnesses find extensive application in a wide variety of appliances including but not limited to:
The manufacturing process, of course, begins with the design aspect. The wire harness needs to be custom designed for each product. What is also imperative is to choose the components of the harness carefully and be mindful of all specifications.
Since the wire harness plays a critical role, prior testing is mandatory. What this means, is to create a functional prototype so that the harness can be tested in its intended application. This way you can be sure about the harness before beginning the first production run and there are no costly errors to contend with at a later date.
The production of the wire harness leaves little room for error, so all design specifications need to be met. It is important to remember that despite some level of automation, the manual assembly still plays an important role in the wire harness manufacturing process. This is on account of the fact, that wire harnesses and cable assemblies involve some intricate steps that need manual intervention. Since wire harnesses need to be customized for individual applications, the role of manual assembly further increases. They resolve geometric and electrical issues in the products. They also ground and protect wires from both external and internal damage. Also, the advantage of manual production is its cost-effectiveness.
Broadly speaking, the steps involved in building the wire harness involve:
Post production, comes the important stage of testing where each wire harness goes through a process of safety testing. This is a crucial process as it ensures that the product performs up to its potential. The harness needs to be checked for continuity as also for construction and labeling.
To sum up
It is important to remember that the more detailed your documentation is the fewer issues will be faced on the assembly floor. Some of the information that should be provided to the contract manufacturer includes:
The contract manufacturer will be in a position to offer a number of recommendations to do with the following aspects:
It is advisable that you give generic specifications for the wires. That way the PCB manufacturer can go with what works best for the harness and what is cost-effective. With due attention paid to the above issues you can ensure that you help speed the overall manufacturing process as also receive a quality product.
At Technotronix, we have 40 years of experience in manufacturing and assembling industry-leading printed circuit boards, cable, and wire harness assemblies. Equipped with state-of-the-art equipment and skilled personnel, we offer wire harness assemblies to meet your bespoke requirements. Technotronix can be your trusted PCB manufacturer who will give you ample smart solutions related to printed circuit boards.
When it comes to making iPhones, every part counts, especially the circuit boards. These tiny… Read More
In the world of printed circuit board (PCB) assembly, testing plays a crucial role in… Read More
In the world of gadgets, flexible printed circuit boards (Flexible PCBs) hold the utmost importance… Read More
Introduction Advancements in technology have revolutionized the landscape of electronic devices, ushering in a new… Read More
With the rising popularity of electric vehicles (EVs), there's a growing need for better charging… Read More
In today's fast-paced manufacturing landscape, where precision and reliability hold paramount importance, the evaluation of… Read More