Industrial Wiring Harness

• Wire: Typically a copper or aluminum wire with insulation used to transmit power and signals.

• Connectors: including terminals and plug-in plastic shells, etc., used to connect different parts of the wiring harness or to connect to equipment interfaces.

• Sleeving: Such as corrugated pipe or PVC pipe, used to protect wires from physical damage and environmental influences.

• Use auxiliary materials such as tape, various types of sheathing, and heat shrink tubing to further protect the wiring harness and provide additional mechanical or environmental protection.

The selection and combination of these materials depends on the specific environment and performance requirements of the seat belt application. For example, some harnesses may require additional water or fire resistance, while others may require greater heat or chemical resistance.

Purpose and function: Specifies the specific tasks the wire harness needs to perform, such as transmitting power or signals, and whether it needs to resist vibration or electromagnetic interference.

Wire selection: Select appropriate wire specifications based on electrical requirements, including wire specifications, current carrying capacity, conduction current, etc.

Environmental conditions: Consider the environment to which the harness will be exposed, such as heat, moisture, or chemicals, and select appropriate materials and protection.

Mechanical properties: Ensure that the wire harness can withstand mechanical stress, such as bending or twisting, while keeping its electrical properties intact.

Abrasion Resistance: If the harness is subject to rubbing or scratching, it should have good abrasion resistance.

Manufacturing process: Consider the manufacturing process of the wire harness, including steps such as stripping, crimping, assembly, and testing.

Quality Control: Continuity testing, insulation testing, and functional testing are performed to ensure that the harness meets safety standards.

Maintenance and maintenance: The convenience of maintenance and upkeep of the wiring harness should be considered when designing.

Life expectancy: The design life of the wire harness is estimated based on the use environment and maintenance conditions.

Custom Requirements: Depending on specific application requirements, the size, layout, and components of the harness may need to be customized.

The manufacturing process of industrial wire harnesses is a series of carefully designed, sequenced steps designed to ensure that the quality and performance of the wire harness meet specific industry standards. The following are the basic steps for manufacturing industrial wiring harnesses:

Incoming inspection and storage: First, the raw materials are inspected to ensure that the materials meet production requirements and are properly stored for use.

Cutting: Cut, peel and bundle wires of different specifications according to design drawings and process documents.

Crimping: Connecting wires and terminals together using a crimping machine to ensure the connection is secure and meets technical specifications.

Subassembly: Assemble the crimped semi-finished products with other parts such as sheaths, pipes, rubber parts, etc. into new semi-finished products.

Assembly: Combine a variety of semi-finished products and materials into a complete wire harness, tied with tape or zip ties.

Inspection: Conduct appearance inspection, functional inspection, electrical inspection, etc. to ensure that each finished product meets quality standards.

Packaging: Arrange the qualified wire harnesses neatly, package them, affix the certificate of conformity and serial number, and finally put them into storage.

This process requires precision equipment and experienced engineers to ensure accuracy at every step, resulting in high-quality industrial wire harness products.

The wiring method of industrial wire harnesses needs to consider many factors to ensure the safety, reliability and efficiency of the wire harness. Here are some key considerations when wiring:

Wire harness classification: Classify and bundle wire harnesses according to the type, frequency, power, etc. of wire transmission.

Grounding requirements: Twisted pairs, multi-strand cables, and shielded cables need to be grounded at both ends or at multiple points.

Avoid heat sources: Wire harnesses should not be placed near heating components.

Protective measures: When the wiring harness passes through sharp angles or places where the wires may be scratched, protection should be provided.

Fixing method: Use clamps, cable ties, hoops, wire troughs, and brackets to fix the wire harness. When sealing the cavity, be sure to use perforated rubber pieces to protect the cables.

Bending radius: Choose an appropriate bending radius, usually 8-10 times the outer diameter of the cable as the bending radius of the drag chain.

Wiring of moving parts: The cable of the drag chain should be a mobile cable, and ensure that the distance between the cable moving point and the end of the drag chain is 10-30 times the outer diameter of the cable. Prevent twisting: When wiring without twisting the wires, the side wire angle should not exceed 5°.

Cable clearance: When implementing horizontal wiring in a drag chain, sufficient clearance must be ensured.

The clearance between cables should be at least 10% of the outer diameter of the cable. These guidelines help ensure the performance and safety of industrial wiring harnesses during wiring, while also helping to increase the longevity and ease of maintenance of the wiring harness.

Visual inspection: Check the wiring harness for obvious damage, such as broken wires, fraying, or corrosion.

Electrical Testing: Conduct continuity and insulation tests to ensure there are no breaks or shorts in each wire in the harness.

Functional testing: Verifies that components such as relays and switches in the wiring harness work as expected.

Image Inspection: Perform an image inspection of the wiring harness with the fuse box to determine if the safety plug and relay plug are in the correct position.

Torque detection: Check whether the torque of the bolts in the fuse box meets the regulations.

Wire harness standards: Ensure that the wire harness meets the standards of the industry and region where it is used, such as EU VDE certification, US UL certification, etc.

Terminals and wires: Select the appropriate terminal model and wire model specifications based on the device’s wiring method, current carrying capacity, wire diameter, and application scenarios.

Matching equipment interface: The design of the wiring harness should match the interface on the equipment board to ensure the reliability of the connection.

Environmental adaptability: Choose a wire harness type that can adapt to the working environment conditions of the equipment, such as high temperature resistance, high pressure resistance, flexibility, wear resistance, etc.

Quality and safety: Pay attention to the quality and safety of wires and choose products with reliable quality and safety standards.

Moisture and dust-proof: Ensure that the wiring harness is not affected by moisture and dust, preventing corrosion and damage.

Avoid mechanical damage: During transportation, the wire harness should be protected from being squeezed, bumped, or dropped, especially at low temperatures, otherwise it may cause the insulation or sheath to break.

Proper Packaging: Use appropriate packaging materials, such as pearl cotton or bubble bags, to protect fragile connectors.

Clear identification: Each wire harness should have a fixed label or product nameplate in a visible location, including product name, model, manufacturer, production date or batch number.

Storage environment: The storage warehouse should have tight doors, windows and ventilation channels, which are dust-proof, moisture-proof, and protected from sun and rain. The relative humidity should not exceed 70%, and the temperature should be controlled within the range of 10°C to 30°C.

Avoid chemical corrosion: Do not come into contact with corrosive substances such as acids, alkali and mineral oil, and should be stored in isolation.

Storage period: The storage period of cables is usually limited by the date of manufacture, which generally does not exceed one and a half years, and the longest does not exceed two years.

Poor contact: Due to unreasonable design, incorrect material selection, abnormal processing dimensions, etc., poor contact of the metal conductors inside the terminal may occur.

Poor insulation: Due to reasons such as steel residue on the floor or inside, floor dust, flux or aging of insulating materials, insulators will be contaminated by moisture, resulting in short circuits, leakage, breakdown, low insulation resistance, and poor insulation.

Poor fixation: Insulators not only insulate, but often also provide precise neutralizing protection for extended contact. Poor fixation can lead to contact reliability issues or even product disintegration.

Short circuit fault: Due to external extrusion and impact, the cables inside the wiring harness are damaged, resulting in an intermediate short circuit fault.

Iron: If the power cord is short-circuited, there is nothing missing between the cable sheath and the power cord terminal, but the copper core cable is short-circuited to the power cord terminal.

Burnout: Due to human factors such as overload, short-circuit fault, unscientific installation position, incorrect wiring, etc., the wiring harness may be burned out.