What to Look for in a Cable Harness Manufacturer

Cable and harness assembly typically requires connecting different wires to enable electrical current to travel through the connection. The most common methods of connecting wires are soldering and crimping. Both processes help create secure connections for cables, and they produce long-lasting and high-performing cable connections.

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Crimping

Crimping is the process of installing connectors on the ends of cables using a crimping tool, and involves stripping, cutting, and crimping terminals on either side of the wires. Whether manual or automated, proper wire crimping requires specialized tools and materials and must follow certain steps. High-quality crimps form gas-tight joints, which result from compressing specially designed splice bands or crimp terminals with cables and wires. Gas-tight connections prevent corrosion from moisture and oxygen.

Terminal crimping reshapes the strands in a wire to form a low-resistance electrical connection. The connections must be strong, with a single joint that has no breaks or segments, and the crimp must meet the height and width specifications established by the terminal manufacturer. It is important to avoid overly tight connections, as this can reduce the cross-section of the wire.

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Wire harnesses and cable assemblies have become essential components across many industries, from aerospace to automotive. These smart systems are designed to organise and create space while also allowing for the transmission of a signal or electrical power. Wire harnesses and cable assemblies are efficient, not just in terms of what they do but also when it comes to the process of manufacture, and they have a lot of benefits wherever they are being used.

What are wire harnesses and cable assemblies?

They can vary in size and composition but they are essentially the systematic and integrated arrangement of cables, usually inside an insulated material. Some may be small and simple while others may involve the complex arrangement of hundreds of cables or wires. One of the main reasons they have become so popular is because they bundle cables or wires together in a ready to install package that saves a lot of time and effort and ensures that installation is always correct and complete. Wire harnesses and cable assemblies can be pulled together using a range of different materials, from simple cable ties to straps, cable lacing, sleeves, electrical tape, conduit or a combination of each of these.

The advantages of wire harnesses and cable assemblies

• They save a lot of time. One of the major benefits of wires harnesses and cable assemblies is the way they can be used to simplify manufacturing processes. No matter what the industry, where cables and wires are required, using wire harnesses and cable assemblies can considerably cut down the time involved. Even where many miles of cable are being installed, the use of wire harnesses and cable assemblies &#; which can simply be pre-assembled and then dropped in where required &#; makes everything simpler and reduces the manufacturing time necessary for each item.
• Raising safety standards. Wire harnesses and cable assemblies may have many different functions within an individual design but they will all ensure that the wires and cables involved are kept in place and remain secure. This means they are less likely to be affected by factors such as vibration, moisture or abrasion. When the wires are bundled in a flame retardant material this can also considerably reduce the risk of an electrical fire.
• Bespoke and effective. Wire harnesses and cable assemblies are designed for a specific situation using the geometric and electrical requirements of the equipment they are going to be installed in. This can have many benefits, including helping to optimise space inside equipment and avoid previous issues, such as reducing the potential for an electrical short, as wires are in a non-flexing bundle.
• Testing and quality control. Wire harnesses and cable assemblies go through a rigorous testing process that is designed to ensure electrical functionality thanks to a pre-programmed test board. The end product is only sent out to customers once it has been 100% approved and passed by quality control.

Wire harnesses and cable assemblies offer efficiency, effectiveness and a bespoke solution to wiring and cable needs across any industry. We are one of the UK&#;s leading wire harness & cable assemblies manufacturers, contact our sales team today&#;

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