What Is the Importance of Wiring Harness?

Where is a Wiring Harness Used? 

A wiring harness, also known as a wiring assembly, refers to an integrated and systematic arrangement of cables (wires) within an insulating material. They are built to transmit electrical signals and are used in electrical systems. A diverse combination of wires, electrical tape, straps, and conduits, is used to create a wiring harness. 

Though transmitting electrical signals is the primary goal of a wiring harness, in the bigger picture, these electrical components are much more important than you’d realize. The harness makes connecting to larger components easier by combining the wiring into a single unit for a "drop-in" installation. Instead of multiple cables running in parallel, a wire harness provides a centralized connection point that is safe.

Importance of Wiring Harness 

Now that we know the basic definition of a wiring harness, let us discuss the importance of a wiring harness in detail. Not only will this help you get better insight into its purpose, but you also see how different harnesses can be used in different circumstances. 

Facilitates Application 

Cables or wires connected outside a harness are likely to get messy. A wire harness clears the area of clutter and gives electrical transmission a single source of connection, and a tidy, organized appearance.  Therefore, it is easier to connect a single group of clamped wires to one connection rather than having numerous wires, each connected to a different set of slots.

Quality & Durability 

An important characteristic of wiring harnesses is that they are manufactured using computerized machines reducing the chances of defects. 

These computerized machines also have a system of automatic testing to make them even more secure. Because of the wiring harness’s innate robustness, there is almost no chance of failure. Such advancements in our electrical engineering systems are one of the biggest ways in which the importance of wire harnessing in industries is visible. 

Time-Effective Installation

There are kilometers of wiring required to put together a single piece of equipment. Installing all these wires individually and manually is a daunting task. When all these cables and little parts are integrated into a single apparatus, a tremendous amount of manufacturing time is saved. Such an organized system also reduces the chance of human error. 

Remember that time is money. When you save huge amounts of time in manufacturing, you also save money and effort. Further, in the long run, a wiring harness may play an important role in avoiding future problems.  

Secure Connections 

When wires and cables are bound together systematically in a single harness, a variety of security issues are resolved. The wires are protected from damage from moisture or abrasions as they have a defined position. Wires placed in a non-flexing bundle ensure the optimal utilization of space. Further, a wiring harness is also extremely functional in preventing short circuits and fires, because the harness is always created inside insulated, secure material. 

Manufacturing and Designing Wiring Harness

Three essential parts of a wire harness remain the same. These include: 

• Wires 
• Connectors 
• Terminals

All of these components are important in determining the overall performance and dependability of a wiring harness. Be it the types of connectors used in wiring harness, types of terminals used in wiring harness, or even the types of clips used in wiring harness - little parts make most of the difference. 

You must already know what wires are. Let us unpack the definition of connectors and terminals to understand harnessing better. 

Connectors 

Wire harnesses are connected to power sources or circuits using connectors. These are electromechanical devices whose main function is to create a continuous electrical signal. 

There are two types of electrical equipment you will often come across when speaking of the types of connectors in wiring harness: Male-ended plugs and female-ended jacks.  They usually come in pairs, with the male-ended plugs fitting into the female-ended jacks.  Depending on their application,  they are available in a wide range of sizes, shapes, materials, and qualities. This may include circular, header, pin, crimped, and multitap.

Terminals

Terminals are the pins in connector housings. They are the points where wires in the harness either end or connect to another component. They conduct electricity to secure connections in the harness. The designs, shapes, and sizes of terminals are diverse and are used as per applications. For example, terminals used in engine wiring harness will be different from those used in medical equipment. 

Classified by functions, terminals can be wire-wrapped, soldered, press-fit into a ribbon connector, or crimped connections. They are also classified in terms of shapes, including flagged, ring, spade, hook, quick-disconnect, bullet, and spade.

Conclusion 

A wiring harness refers to a systematic and integrated electrical framework within an insulating material. The importance of wire harnessing in industries can be seen clearly in the multiple applications it has across fields such as automobiles, aeronautics, machinery, construction, and much more. For any student in electronics or aspiring mechanical engineer, understanding wiring harness should be a high priority. 

Here at Skill-Lync, we offer multiple courses in mechanical and electrical engineering. We have a specific course on Automobile Wiring Harness that can help you learn much more about wiring harnesses and help you establish a career. We are here to answer any of your doubts and queries about our courses.