What Is a Cable Harness?

A cable harness is a group of wires and cables that transmit electrical signals or power. Harnesses also contain connectors and binding materials like heat-shrink tubing, wire ties and lacing.

A good cable harness manufacturer will have the parts and know-how to produce your harness according to design specifications. They will be familiar with sourcing parts that are widely available, cost effective and less susceptible to supply chain disruptions.

Wires

A wire harness is an efficient way to organize electrical wiring. It consists of a bundle of cables and wires bound together by terminals or connectors, and can include a number of other elements like switches, diodes, and fuses. Its primary function is to transmit signals or electric current. To accomplish this, it must be constructed with a conductive material that can withstand high levels of electric current.

The design process of a cable harness begins with the development of a schematic. This diagram serves as the blueprint for the wire harness and includes all of its components. It also details how the components will be connected and what type of materials are used in construction. Once the design is complete, the wires are cut to the correct length. They are then stripped of their insulation to expose the bare metal conductors. This step can be done manually or using automated equipment.

Wires and cables that make up a wire harness are typically wrapped in non-conductor heavy duty materials that offer a degree of protection against cable harness environmental conditions. This tough insulation material can withstand heat, moisture, dust, and abrasions. This can prevent the wires from becoming entangled and reduce the risk of an electrical short circuit. In addition, it can help save space and make the assembly more robust.

Connectors

The connectors in a harness are the points at which wires connect with other components to relay data, control signals, or power. They come in a variety of sizes, shapes, and pin counts to match the specific electrical needs of a system. The most common types of wire harness connectors are plugs (or male connectors) and jacks, which are often used in pairs to form an electronic signal circuit.

A cable harness can be surrounded by outer sheathing or insulating material to protect it from physical damage and environmental elements like moisture and dust. It can also feature conduit to guide cables through tight spaces and reduce flexing.

Stray wires can be a safety hazard, especially in industrial settings where space is limited. Harnesses group cables sensibly and contain them to prevent accidents in the workplace. They can also incorporate structural supports and insulation to improve durability.

In addition to wire harness connectors, a cable harness may include other connecting mechanisms like cable looms and electrical tape. These devices bundle and secure the wires to prevent them from tangling or forming shorts. They can also be equipped with terminal blocks, which offer modular connector pins for easy wiring without soldering. Other connecting mechanisms include fuses, which stop surges of electricity from overloading and damaging the system, and relays, which turn higher-amperage circuits on and off.

Shielding

Conductors in cable assemblies emit electromagnetic interference (EMI). cable harness supplier EMI can disrupt other components or damage signal transmission, and proper shielding is crucial. Shielding encloses the wires in a harness with a conductive layer to act as a Faraday cage and block out electromagnetic fields. It increases the cable’s thickness, adds weight, and reduces flexibility, but it’s critical to protecting your electronics from EMI.

Different environments require different levels of EMI protection. For example, a loud factory floor will require more effective shielding than a quiet data center. To combat EMI, we use a variety of methods including foil, braid, and spiral shielding.

Foil shields consist of thin layers of copper or aluminum attached to a polyester sheath and offer excellent coverage of the cable and wires underneath. These shields are often grounded with a drain wire and provide 100% coverage of the cable or component. Foil shields also provide good abrasion resistance and cut protection for the conductors in a cable.

Braided shields use a woven pattern of tinned copper wire to create a flexible cylinder that protects the cables or wires from EMI. The tight weave may leave small gaps in coverage but typically provides between 70-95% interference protection. Braided shields are easy to terminate and work well in most noisy applications, but they do add bulk and cost to the overall project.

Labeling

In a cable harness, labeling is used to convey wire and component information. This allows technicians to quickly identify a problem and determine whether it is the result of a loose connection, short circuit, or other issue. This ensures efficient troubleshooting and enables compliance with industry standards. It also facilitates efficient production processes and optimal product design.

Some harnesses utilize color coding to differentiate wire groups. While this method can be effective, it is important to note that color conventions may differ between organizations. This can cause problems when a wire bundle from one company is integrated into another company’s product. In these situations, it is best to use printed markers that transcend color-based ambiguity.

These labels are typically made of a self-laminating wrap or heat-shrink tubing that can be applied to a wire end during assembly. They provide durable, abrasion-resistant markings that can withstand harsh environments. Additionally, they are available in many colors to meet a range of identification needs.

Other labeling options include thermal printers, which use a variety of ribbons and materials to print custom labels for various types of PVC tube. These printers are ideal for a wide range of applications, from cable labeling to industrial pipe identification. They also allow users to customize their label text, facilitating better inventory management and easier documentation.