Cable assembly or wire harness is the systematic integrated arrangement of cables within an insulated material. It is used in the electrical system of machines. Most electrical systems are cramped with many cables of different colors and sizes. Each electrical wire represents a unique function. With so many cables running within a system, a harness provides one common connection point.

Wiring is a complicated process handled efficiently only by professionals. Generally each wiring system comes with a schematic. A wrong connection in the circuit interferes with the function. Instead of numerous single connection point wires, having a common connection point in place reduces the probability of error.

How does wire harnessing work?

Wire harness manufacturing is a lucrative market with many big communication companies competing for the top slot. The design of cable harness is solely dependent on the electrical and geometrical requirement. The production is mostly manual with preliminary automated crimping of the wires. The wires are first cut to the required length and then connected to the terminals or connector housings. The cables are then clamped together.

Manual work includes routing wires through sleeves, crimping with fabric tape on wire strands, fastening strands with tape, clamps or cable ties. The automated pre-production work covers cutting wires using wire cutting machines, twisting wires and soldering the ends.

Advantages of using cable harness

Security and safety: The cables are better secured when arranged in a harness of insulated material. The non-flexing bundle diminishes the chances of a short-circuit and reduces abrasion as well as moisture related damages. A single wire is relatively easier to install as compared to multiple wire system. Installation time is reduced and the process is simplified as well as easily standardized. Covering the wires in a fire resistant material nullifies the chances of electrical fires.

Simplified use: One clamped wire unit is simpler to handle than individual wires. A typical example of wire harness is the car audio system. Instead of connecting each wire individually to its respective slot, a bunch of clamped wire unscrambles the electric circuit by linking connection A to connection B – both being harnesses.

Reduced clutter: The necessity of an external coating of PVC or non-flexible tubes is canceled out. Space is conserved. Installation becomes simpler and over hauling is fuss-free.

No time lost: Cable harnessing works on a ‘plug and play system’. They are ready to be used post-installation. They are designed in a way to fit exactly into the space that they are meant for. Many industries also vouch for wire harnesses’ efficiency. They are proven to reduce the time taken for production of certain equipment.