25 Oct THE PROCESS OF MANUFACTURING WIRE HARNESSES
Many of today’s technologies rely on a dependable and high-quality electrical harness operation. An electrical harness may simply look like a bunch of wires bundled together but it may be considered as the foundation of many modern mechanized operations. An electrical or wire harness is a systematic arrangement of different insulated wires that distribute electrical current on a specific device.
Some of the industries that commonly rely upon an electrical harness operation are the automotive and manufacturing sectors. It’s basically used to simplify and streamline what is otherwise a complicated series of wiring systems. An electrical harness operation is not to be confused with a cable assembly. A cable assembly typically only has two ends while an electrical harness often has multiple ends or breakouts that branch out into different terminations.
The Benefits of Installing a Wire Harness
Installing a good quality electronic harness operation is proven to make the entire system more efficient. It reduces the installation time of the wiring system as a whole in any device because instead of fixing the wires individually, it allows the manufacturer to install the entire system as one single electronic harness.
A harness also protects the wiring system from any external forces that may potentially damage it. It secures or fastens the wires and keeps them much safer from vibrations and moisture. It also reduces any risks of short circuits as electronic harnesses are typically coated with flame-resistant insulators.
How Are Wire Harnesses Manufactured?
An electronic harness operation started gaining popularity in the 1920s with the automotive industry still in its early days. Engineers discovered that by simply binding wires and cables into a harness, they can reinforce the whole wiring system of a device.
In the same era, with the rise of marketing in terms of household appliances, a better way to manage the complex wirings was in demand. Prior to that, fixing the wiring and cable system proved to be inefficient and time-consuming for the whole large-scale manufacturing process.
The Process of Fabrication
Many companies are proud of the creativity that goes into the engineering of their products. Typically, the wiring design process for a piece of new electronic machinery begins with specialists creating a schematic diagram for the wire harness manufacturers. These diagrams serve as an instruction for the fabrication process and may come in different versions depending on the product that the client needs and the manufacturers.
These schematic diagrams are often analyzed by the engineering team of experts from the manufacturers to figure out how the fabrication process will take place. Revisions are also a big part of the whole manufacturing process as some parts may need some adjustments and updates to make them more suitable for the product they will be placed in. It’s a process usually done to ensure that the best quality is achieved. It’s also sometimes necessary for the engineers to see the product physically so they can fully understand how it works.
Cutting and Prepping
Once all the planning is finalized, it’s time to put all the schematic diagrams or instructions to use in the process of cutting and preparing. Software is typically used to ensure a standard quality when it comes to cutting and binding the different wires. The machines used by the manufacturers can perform accurately when it comes to measuring and sorting the components. Some machines can even twist and group the wires according to their specific uses.
It’s also important to know that the ends of the wires are usually stripped mechanically. This is done to expose the wires that will be attached to terminals or other components. A manufacturing execution system is typically utilized in order to strictly follow guidelines and protocols for consistency. It minimizes any sort of errors in terms of functionality and it also optimizes production by increasing efficiency and accuracy, which can only be achieved with mechanized systems.
The wire bundles that were newly extracted from the cutting procedure are normally grouped into sets during welding and twisting. While the cutting process is usually automated, pre-assembly is usually carried out by highly skilled personnel. Usually, all of these methodological procedures are carried out in separate departments with workers coming together to check for any flaws and ensure quality.
Mounting an Electrical Harness Operation
The next step is to secure or mount the wires onto a harness board. Typically a device that utilizes a wire harness has a panel that allows it to distribute and branch out the cables systematically. The process of mounting is like any typical production you would see in a manufacturer’s facility. Workers gather in an assembly line and follow the standardized instructions to scrupulously mount each component into the right place.
This process includes installing and routing various cables and wires. It also means fastening and binding the components together. Since everything is typically done manually, production can sometimes take longer than others depending on the complexity of the harness design. Electrical harnesses vary depending on the unit it was designed for and the process of mounting may be different for each harness being fabricated.
Post Production Testing
Testing is an essential final step to any kind of production in any industry. Product testing for an electrical harness operation not only ensures the quality but also the safety of the customers. Without any kind of testing process, any malfunctions can prove to be detrimental to the entirety of a brand so meticulous trials are often practiced.
Before an electrical harness operation is deemed valid for distribution, it undergoes a series of quality checks and testing. Each harness is composed of numerous parts that serve different functions so checking each detail is completely necessary to avoid any kinds of problems post-distribution.
It’s also common to use software that tracks the production process of each component. It notes the parts and the individual that was assigned to the assembly for convenient tracing. This makes it a lot easier for companies to recall any batches or products that might be considered not up to standard or have caused failures or malfunctions.