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What is wire harness cable assembly manufacturing

A cable and wire harness also referred to as a wire harness, wiring assembly, cable assembly or wiring looms and harnesses, is an assembly of electrical cables or wires which transmit signals or electrical power. The cables are bonded together with a durable material such as vinyl, rubber, electrical tape, conduit, a weave of extruded string, or a combination thereof. Commonly used in automobiles, car, and construction machinery, cable harnesses has several advantages over loose wires and cables.

Application and environment are the two major factors that determine the types of the wire harness. Based on these two factors, there are 3 types of cable harness assembly.

Open Bundle:

The cable and motorcycle wiring loom tape are attached to the connectors and lugs and are coupled in bundles with various breakouts using plastic tie wraps or waxed lacing twine.

Closed Bundle:

Wires are bundled with a covering, such as pulled-on braided tubing, braided-on Nomex or nylon, or in some cases, metal braid.

Waterproof Harnesses:

The junctions between the legs and backshells of the connectors are molded with a material such as urethane or rubber compounds.

Components of Cable Harness

Wire

The role of the wire is to carry current to convey signals and provide power. It itself contains internal copper wires and external insulating materials. Commonly used specifications have a nominal cross-sectional area of 0.3, 0.5, 0.85, 1.25, 0.3, 0.5, 0.8, etc. Wires, each of which has a current value that allows the load, and reasonable use of electrical equipment for different powers, is the basis for a qualified harness. With the increase of the functions of automobiles, the widespread use of electronic control technology, more and more electrical components, more and more wires, the thicker and heavier the wire harness assembly becomes. In the future, the use of wires will be reduced, and modern cars have introduced CAN bus configurations using multiplex systems. Compared with the traditional point-to-point configuration of the wiring harness, the CAN bus greatly reduces the number of wires and connectors, making the cable wire harness lighter and not limited.

Connector and Terminal

After the terminal and the electric wire assembly are crimped according to the standard, they are locked in the slot of the connector, and the male and female connectors are butted to meet the loop between the harness and the harness to the terminal. If it is arranged in the high humidity environment of the engine compartment, according to National regulations require that waterproof plugs be added.

Exterior Parts and Other Components

The exterior parts include a bellows, a polyethylene tube, a polyethylene cloth, a sheath, a sponge, a tape, a wire fastening harness bracket, etc., in order to place the wire to wear and break. Meet the temperature and humidity requirements of different positions of the body. Generally, corrugated pipe, polyethylene pipe, polyethylene cloth, hard pipe, and sheath are used to prevent the wire from being worn and broken. The wire is wrapped with thin-walled and thick-walled tape, and the wire harness is fixed at a suitable position in the vehicle body by using clips of different shapes. The purpose of the rubber ring is to prevent the wire cable harness from being scratched when it passes through the gold hole.

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