Everything to know about wiring harness engineering

1.What is a wiring harness?
A wiring harness is a collection of wires, cables, and connectors that are bundled together in a specific arrangement to transmit electrical power and signals between different components and systems in a vehicle, machine, or other equipment. The harness acts as a central nervous system for the equipment, ensuring that all electrical connections are properly organized, protected, and functioning correctly.

Wiring harnesses can range in size and complexity depending on the equipment they are used in. They are commonly used in automobiles, aircraft, construction equipment, and industrial machinery, among other applications. Wiring harnesses can be made from a variety of materials, including copper, aluminum, and synthetic fibers, and can be designed to withstand harsh environmental conditions such as heat, vibration, and moisture.

In addition to providing a neat and organized way to manage electrical connections, wiring harnesses also simplify the installation and maintenance of electrical systems, and can reduce the risk of electrical faults or fires caused by improperly connected wires.
2. Purpose of wiring harness components

Wire harness assemblies can be used for a variety of purposes. Agriculture, automobiles, communications, new energy mobile energy storage, solar photovoltaics, manufacturing and medical industries are all included in the application list. Wire harness assemblies are a common feature found in electrical systems around the world. Without them, modern technology might not be as effective.
3.Basic process of wiring harness design

Requirements gathering

Study & analyze data pack

Schematic design

3D routing & material selection (BOM)

Flattening & manufacturing documents

This includes detailed instructions on the routing of the wires and connectors, as well as any other relevant information, such as torque specifications or heat shrink requirements.

Prototyping and testing

Once the design is complete, the harness is typically prototyped and tested to ensure that it meets the requirements of the target application and any relevant industry standards.
4.Production and quality control

Finally, the harness is produced, and a quality control process is implemented to ensure that each harness is manufactured to the same high standards and meets the necessary performance and reliability requirements.

5.Common errors to avoid in wiring harness design

Improper wire selection

Inadequate strain relief

Improper bundling

Inaccurate labeling

Inadequate testing

By avoiding these common errors, designers can ensure that the wiring harness performs reliably over its lifetime, minimizing the risk of failure and reducing maintenance costs.

6.The most important parts of a wire harness are:

Wire: The signal or current that powers a device is carried by the wire. The voltage or bandwidth that the wire is expected to transmit must be met or exceeded by its capacity. The majority of wires are copper, and they can have a coating of your choice.

Connectors: To connect various types of wires, wire connectors are available in a variety of sizes and varieties. They are typically made of plastic, but they can also be made of ceramic and metal.

Fuses: Fuses prevent power surges from damaging or overloading devices on their receiving side. Different types of fuses are utilized by various harnesses. They typically have a rating of 32 volts or less, but this can change depending on the amperage they have.

Grommets: Insulators, grommets prevent moisture from entering the connector. A grommet can be a part of the connector or be attached to the terminal by itself.

Outer coverings/Insulators: Insulators, also known as tubes and sleeves, offer protection from electrical shock, environmental protection, and some degree of abrasion resistance. They can be made of nylon or polyolefin, among other materials.

Relays: Higher amperage circuits are turned on and off by relays. Harnesses are able to power multiple things because of this quality. They differ according to the required amperage, just like fuses.

Strain Relief: Typically added to the connector's exterior. It is made to stop the force that pulls on the wires in the connector from pulling on the terminal, which could cause a bad connection. At extreme bend radiuses, strain relief can also be added, which can put an excessive amount of force on the wire and the connector's terminal.

Terminals: The metal components that are attached to the end of the wire to be inserted into the connector or to a point on the connecting equipment are referred to as terminals.

Ties: The wires that are contained within the harness are held in place in a particular direction by cable ties and clamps. Additionally, it can be applied to a fixed structure to limit movement.

Locks: To prevent the wire's terminal from being pulled out of the connector, locks are inserted into it. It can also guarantee that the terminal is fully inserted into the connector.

7.Conclusion

It can be difficult to create an electrical drawing for your application that includes all of the necessary information, such as schematics, harness layouts, and service documentation. It necessitates a thorough understanding of all components and influencing factors, not the least of which is an understanding of electrical requirements and limitations. Shenzhen Smart Connection Technology Co., Ltd.specializing in electrical assemblies, can assist in streamlining the procedure and making your final product more effective and efficient. For assistance keeping your project on track, take a look at our wire harness design services.