Consolidated Electronic Wire & Cable can assemble a variety of such harnesses, and our experts can help you determine what will fit your needs. However, if your needs are especially complex or specific, we also offer custom harnesses.
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Wires and cables are indispensable tools for a wide range of today&#;s home and industrial systems, and harnesses allow technicians to create orderly, carefully fitted wiring solutions for any type of environment. Depending on the specific needs of an application, these harnesses can be built to accommodate systems up to 600 volts (UL) or volts (military), with high performance at temperatures ranging from -65 °C (-85 °F) to 250 °C (482 °F).
When evaluating a new cable or wire harness solution, remember to carefully consider the specific environment it will be used in and the temperature and conditions it will be exposed to. Evaluate all of the different cable types you may be able to use; custom wire and cable harnesses can be crafted with nearly limitless style and material options, including:
We take a strategic engineering approach to select the most ideal shielding and connectors for your application. At the same time, we take into account all applicable regulatory standards to ensure that your final harness is safe, reliable, compliant, and effective.
Whether the harness will be exposed to continuous flexion
If the harness will be used indoors or outdoors, and under what specific conditions
How many circuits and conductors are required for the assembly, as well as their characteristics
Level of voltage to be carried
Potential exposures, including chemicals, corrosive fluids, weather conditions, and moisture from other sources
Maximum, minimum, and average operating temperatures, as well as potential fluctuations
Local safety and environmental regulations that might impact component selection, installation, and inspection
Routing, breakouts, general shape of form
Since wire harnesses can be used to solve such a diverse range of interconnection challenges, they are used extensively throughout myriad industries. Virtually any industry that relies on cable arrangements can benefit from the use of wire harnesses. The following sectors, among others, often rely on wire harnesses to maximize efficiency and protect employees against the dangers of haphazard wiring:
Wire assemblies are used in an expansive range of aerospace products, such as drones, satellites, and aircraft to facilitate the transmission of power, communication, and more.
Wire harnesses are critical for saving valuable space within automobiles within the dashboard, under the hood, lighting/signals, and more. They are also important for organizing complex wiring in such a way that technicians can easily identify their purpose.
. Hospitals and clinics rely on wire harnesses to organize and protect wires in and between equipment, including crash carts, diagnostic and imaging equipment, dental equipment and more.
. Wire harnesses optimize use of space in a variety of telecommunications equipment, such as modems, routers, repeaters, and a variety of other communication and broadband equipment.
. Nearly all computers, laptops, servers, and other IT technology contain wire harnesses to optimize space and organize wires for easy identification and installation by technicians.
. Wire harnesses are widely used within structures to provide wiring insulation and organization.
. CNC machines and other powered manufacturing equipment rely on wire harnesses to route and organize external and internal wiring.
. Wire harnesses are used on most automated equipment and robotics to safely route, group, and protect critical wiring
Wire harnesses would not be so widely used if they didn&#;t present substantial benefits for wiring applications. Among other advantages, wiring harnesses benefit companies in the following ways:
Decreases cost compared to multiple individual assemblies
Improves organization, especially when a system relies on hundreds of feet of complicated wiring
Decreases installation time for projects involving extensive networks of wiring or cabling
Protects conductors from the elements outdoors or from chemical and moisture exposure indoors
Provides a safer work environment by cleaning up loose or scattered wires, maximizing space, and preventing trips and damage to wires and cable
Enhances safety by minimizing the risk of shorts or electrical fires
Decreases installation and maintenance time by potentially minimizing the number of connections and organizing components in a logical configuration
The many benefits of wire harnesses stem from very simple design principles. Sheathes protect wires against abrasion or exposure to hazards, minimizing the risk of workplace incidents. Connectors, clips, lacing, and other organizational strategies drastically reduce the amount of space that wiring must occupy and ensure that technicians can easily locate the components that they need. For equipment or vehicles that regularly contend with a web of lengthy wires, a wire harness is sure to benefit everyone.
In addition to ensuring optimal organization, a high-quality wire and cable harness will provide reliable insulation and protection for the conductors within. There are many options for durable harness materials, and it&#;s important to select what is most beneficial for your needs.
Some of the most common insulator materials include:
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In choosing between these and other options, it&#;s important to take into account environmental variables such as operating temperature and moisture. The presence of moisture, for instance, can necessitate a water-resistant material like polyethylene to avoid damage to the conductors.
At Consolidated, we&#;ve been helping clients develop these solutions for more than 100 years. Our custom harnesses and assemblies can be found in a wide range of applications, and all projects are supported by our state-of-the-art production facilities.
Bearing in mind relevant industry standards and specifications such as IPC/WHMA-A-620, there are countless ways to develop a harness or assembly to meet the needs of a particular project. And with various options available for shielding, fillers, materials, identification, and style, the most efficient organizational solution for your project is simply a matter of strategic engineering.
Our current catalog includes a wide variety of robust, high-performance cable and wiring harnesses guaranteed to organize multi-wire systems across industries. Our custom harness services are tailored to each and every client, with our technicians drawing on decades of multidisciplinary experience to determine the ideal strategy for each operation. Whether your cabling is for a home appliance or a state-of-the-art aircraft, our assemblies can enhance organization and safety at a competitive price-point.
To learn more about our custom wire and cable harness solutions and discuss how we can help with your next project, check out our comprehensive eBook, &#;Creating a Custom Cable,&#; or get in touch with our team today.
A cable harness, also known as a wire harness, wiring harness, cable assembly, wiring assembly or wiring loom, is an assembly of electrical cables or wires which transmit signals or electrical power.[1] The cables are bound together by a durable material such as rubber, vinyl, electrical tape, conduit, a weave of extruded string, or a combination thereof.[2]
Commonly used in automobiles, 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 short is decreased.[3] 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.[4] Binding the wires into a flame retardant sleeve also lowers the risk of electrical fires.[3]
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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 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.
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 communication protocol's design standards developed by automotive entities like ASME, ISO or JASO. [5]
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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.[3]
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.[6] After this, the ends of the wires are stripped to expose the metal (or core) of the wires, which are fitted with any required terminals or connector housings. The cables are assembled and clamped together on a special workbench, or onto a pin board (assembly board), 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.[3]
In spite of increasing automation, hand manufacture continues to be the primary method of cable harness production in general, due to the many different processes involved,[3] such as:
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.
Pre-production can be automated in part. This affects:
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."[7] Some types of terminals include ring, tongue, spade, flag, hook, blade, quick-connect, offset and flagged.[8]
Pull test qualification of crimped end.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 being programmed into the test board. The harness is then measured for its ability to function in the simulated circuit.[9]
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 harnesses are consistently effective and safe.[10]
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The cable harnesses used in sound reinforcement and recording studios are called multicores, also known as snakes or looms. They carry audio signals between a mixing console and stage box. Modern digital mixing consoles typically use a single twisted pair cable rather than a traditional analog multicore.
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Although customer specifications take the highest priority when creating cable harnesses of a certain quality,[11] in North America if no such specifications are found the quality standards of a cable harness are standardized by the IPC's publication IPC/WHMA-A-620 for minimal requirements for cable harnesses.[12] 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.[11] The IPC/WHMA-A-620 publication has standards for a wide range of elements within a cable harness, including but not limited to electrostatic discharge protection, conduit, installation and repairs, crimping, pull-test requirements, and other operations that are critical to the production and function of cable harnesses.[12] The standards mandated by the IPC differ based on a product's classification under one of three defined product classes.[13] These classes are:
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The company is the world’s best Wire Harness Manufacturers supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.