25 Oct UNDERSTANDING THE RELIABLE QUALITY BEHIND AUTOMOTIVE WIRE HARNESSES
The modern vehicle is highly reliant on an automotive harness simply because it signals and powers almost every function of a car component. Each automobile has a series of wirings that run throughout its entire body. With new car models today, automotive harnesses have become somewhat of a foundation for the modern automotive industry.
A modern car has complex wiring systems that are engineered to work without failure. Its electrical system consists of numerous components like switches, transistors, resistors, and much more. These parts are all conveniently interconnected by an automotive harness designed to make the linking process more efficient and convenient. Automotive harnesses are also made to withstand external elements and maintain the performance of the car despite any kind of terrain.
Purposes of a Quality Wire Harness
One of the main components of a car is of course its engine. An engine typically has a wiring harness that connects throughout different components that need an electric current to operate like the alternator. Once you insert your keys into the ignition, the engine starts and connects to the fuse of the automotive harness. The power then signals the other components of the car then returns to the engine. Automotive harnesses are also known to reduce any kind of failure or accidents because of how conveniently it distributes the wiring system of a car.
Since it must work with no possible failure, automotive harnesses are made with materials that must be checked for quality. It should be able to withstand high temperatures, especially inside the engine compartment even on a baking hot summer day. Alternatively, on freezing cold winters, wire harnesses can also maintain performance and function through thick snowstorms. In most cases, the cable bundles have two strong connectors on each side, which provide a series of electrical systems to the submodule.
From this electrical module or relay, separate wiring harnesses are attached to each component. There are automotive harnesses for both solenoids and sensors which control the functions of different parts such as transmission and ignition. Many ECU connection problems that trigger a signal or engine light check are not caused by a sensor error but by a wire failure. The data is transmitted from the stress sensor to the ECU so that motion can be adjusted.
Maintenance and Protection
Any moving vehicle is expected to create vibrations with its intensity depending on the surface of the terrain. These vibrations may cause gradual damages over time. Weather changes may also cause unwanted moisture damages that can affect the car’s performance in the long run.
Installing a good quality and dependable automotive harness may be the solution to normal wear and tear issues that may be encountered as the years go by. It allows the wiring of your vehicle to branch out efficiently and be less prone to damages. A good automotive harness should be able to last as long as your vehicle. Maintenance and repairs are also easy as replacement parts are now conveniently available in the market.
Quality in Production
Different automotive companies pride themselves on the creativity that goes into the designs of their vehicles. Typically, the process of designing a wire harness for a new car starts with experts creating a draft for the manufacturers. This may come in different versions depending on the requirements or guidelines according to the company and the unit that it’s designed for.
The automotive harness manufacturers then use this draft to follow the specific requirements during production. It is also not uncommon for changes to be made during the fabrication process as some parts may need to be modified or updated depending on the situation. All this is done to ensure quality and little room for error as it can be detrimental to the performance of the vehicle as a whole.
Usually, to ensure a standardized quality, manufacturers utilize types of software that are designed to do the necessary cutting and binding to fuse together the wirings. These machines can measure, cut, and strip the wires according to the standard size that was designed. Other machines can even go as far as twisting, grouping, and preparing the wires together for the succeeding operation.
Companies have different manufacturing execution systems that ensure protocols and guidelines are followed for uniformity. They also optimize production by increasing the efficiency and precision that can only be achieved through a mechanized system. It reduces the chances for any errors in terms of sorting the wires according to their functionality.
Although the cutting process is typically automated, the pre-assembly is normally done by highly trained personnel. Initially, the wire bundles that just came fresh out of the cutting line are grouped together into kits through the process of welding and twisting. Usually, this whole methodical process is done in a separate department with workers assembled to check the quality of each output.
The final process is done by mounting the wires according to the final design into an automotive harness board. This is something similar to what you can see inside a system unit of a computer with wires branching out into different sections of a panel or board. Like any kind of industrial production line, automotive harnesses are placed in an assembly line where workers meticulously place each component to its rightful area depending on the design. Take note that not all automotive harnesses are alike. Each of them differs according to how engineers and automotive companies designed them to be and is built specifically for the customers.
A newly finished automotive harness must then be checked for quality before it could be deemed valid for distribution. Each one typically consists of hundreds, if not thousands of components so scrupulous checking is very much necessary to ensure the omission of failure. Take note that software is often used to track each component and the individual that was responsible for its assembly. This makes it easier for any defective batches to be conveniently traced and recalled should any problems arise in the future. This type of quality control is often utilized in many manufacturing companies and has proven its efficiency over the past years.