What is an industrial wiring harness?
An industrial wiring harness is a cable used to connect electrical devices. The emergence of industrial wiring harnesses has made power transmission and signal transfer possible. It is employed to link electrical components such as machinery equipment, automobiles, robots, and medical devices. Multiple wires or optical cables are fixed together to form an integrated unit that is convenient for use. Industrial wiring harnesses find extensive applications in a wide range of power equipment and electrical appliances.
Industrial wiring harness structure:
- Wire:It serves a transmission function and is composed of conductive materials such as copper and aluminum.
- insulating material:To prevent short circuits in wires, common materials include PVC, PE, etc.
- Jacket and fasteners:To protect the wires and maintain the integrity of the wiring harness, it can be fixed with wiring hamess tape, which is generally composed of PVC or PE.
- Connector:Electrical connections between devices, including plugs, sockets, etc.
What is the development history of industrial wiring harnesses?
In the 18th century
With the advent of the steam engine, the rudimentary form of the primitive wire binding technology emerged.
With the advent of the Electrical Age in the 19th century
The copper wires wound in Edison's laboratory began to be woven into a systematic network of circuits. During this period, the production of wire harnesses began to show standardization, providing energy for electrical equipment.
At the beginning of the 20th century
The automotive industry began to experience explosive growth. In the production line of the Ford Model T, hand-woven wiring harnesses transformed from workshop craftsmanship to large-scale manufacturing.
During World War II
Strict requirements were imposed on military equipment, giving rise to new standards for waterproof and shockproof wiring harnesses.
In the 1950s
The emergence of plastic insulating materials transformed industrial wiring harnesses into more lightweight wire networks.
The popularization of automotive ECU in the 1990s
Transformed industrial wiring harnesses from conductors into information superhighways, with each wire continuously transmitting data.
What are the applications of industrial wiring harnesses?
The products of industrial wiring harnesses refer to multi-core wires, electronic wires, flat wires, etc., components configured inside the cabinet. It is widely used in industrial UPS, CP, monitors, air conditioning equipment, wind energy and other cabinet facilities. There are also sub-products with a wide range of applications, including network communication, air conditioning temperature control, LED lighting systems, rail transit, Marine and ship engineering, renewable new energy, packaging and logistics transportation, etc. Under normal circumstances, there are also custom cable assembly and wire harness assembly.Regarding custom wiring harnesses, we offer professional consulting services. Click to consult.
Wind power generation wiring harness
Wind power generation connection cables are applied to the connection of frequency conversion systems and the connection of control systems inside cabinets. The cable needs to maintain stable electrical and mechanical performance under conditions of temperature ranging from -50℃ to +80℃. Wind farms are mostly located in areas with harsh climatic conditions. Therefore, the key performance of this product lies in the low-temperature torsional resistance of the cable and the flexibility of the cable at low temperatures.
Railway locomotive wiring harness
Railway locomotive wiring harness products are mainly applied in the connection of power systems, control systems, communication systems (for the connection of railway electrical control systems) and internal electrical systems. Subway vehicles need to evenly distribute the electrical wiring in each unit carriage to ensure the stability of the subway vehicles during operation and the normal use of the braking function. The requirements for the wiring harness are very complex.
Robot wiring harness
The crimping form in robot wiring harnesses is of great significance and has strict requirements. It must be stable and reliable. The cables used in different parts of industrial robots have different characteristics. Generally, robot wires and cables are divided into power circuit cables and signal circuit cables.
Bank equipment wiring harness
Bank equipment wiring harnesses are used in bank equipment, such as LED display screens, interest rate screens, window intercoms, queuing machines, ID card verification devices, etc. ATMS, self-service inquiry machines, self-service payment machines, etc. The terminals of the wiring harnesses generally adopt TYCO connectors /AMP connectors, etc.
Communication data, security wiring harness
There are many types of security system wiring harnesses, such as visual intercom, closed-circuit monitoring, conference systems, anti-theft alarm, access control and attendance, parking lot management, smart home, smart office, and intelligent audio-visual. Currently, the mainstream application terminal customers of security wiring harnesses are Dahua, Uniview, Hikvision, Xiongmai, etc.
UPS series industrial control wiring harnesses
The application of UPS series industrial control wiring harnesses in most industries is of great significance. It can provide high-quality and stable power supply. When the power grid system is out of power, the power supply needs to be maintained to provide a buffer time for protecting the data of the industrial control system and prevent accidents. An industrial UPS power supply is composed of a main unit and a battery. The wiring harness is the power control line, such as the power cord of an electronic computer or the power cord of a switch. In addition, wiring harness kits are widely used in industrial control equipment and application scenarios that require complex circuit connections. Through reasonable design, the reliability of the system has been enhanced, and the maintenance cost is on a downward trend.
Which are the manufacturers of industrial wiring harnesses?
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In the following table, one can understand the major global wire harness manufacturers, their advantageous fields and corresponding characteristics. Especially in the manufacturing of connectors, these brand manufacturers are usually the benchmarks of the industry. If you want to customize connectors and have specific requirements from certain manufacturers, we can cooperate with them. Meanwhile, there are also Chinese manufacturers that can produce them to choose from. For more specific information, you can contact us online and send us industrial wiring harness diagrams and other materials.
| Brand |
Country |
Advantageous fields |
Features |
| TE Connectivity |
The United States |
Automobiles, industry, aviation, communications and medical care |
The largest in the world and with the most comprehensive product line |
| Amphenol |
The United States |
Radio frequency, automobiles, communications, military industry |
Leading technology, high performance |
| Molex |
The United States |
Consumer electronics, data communication, automobiles |
Precision miniaturization |
| Phoenix Contact |
Germany |
Industrial automation, terminal blocks, lightning protection |
Benchmark in the industrial field |
| Yazaki/Sumitomo |
Japan |
Automotive wiring harnesses and connectors |
Automotive wiring harness giant |
|
Luxshare |
China |
Consumer electronics (Apple supply chain) |
The leading consumer electronics company in China |
|
AVIC Optoelectronics |
China |
Military industry, aerospace |
The leader of high-reliability connectors in China |
|
China |
Design, manufacture of industrial cables and flat cables, as well as research and development of supporting products |
Located in the "World Factory", it has established cooperative relationships with many well-known enterprises around the world |
What are the differences between industrial wiring harnesses and ordinary wiring harnesses?
Industrial wiring harnesses and ordinary wiring harnesses have obvious differences in design and application, among which the more crucial ones lie in the selection of current, wire materials and the handling of skin effect.
Industrial equipment is mainly suitable for high-current environments and has high requirements for wires. When current passes through a wire, it concentrates on the surface, resulting in an increase in power loss and resistance. This is a manifestation of the skin effect. The following table compares industrial wiring harnesses with ordinary wiring harnesses from different perspectives, allowing for a clear understanding of their differences.
Industrial wiring harness
It is made by weaving multiple strands of fine wires into bundles, with a complex structure.
Ordinary wiring harness
It adopts single-strand thick wires and has a simple structure.
|
Difference |
Industrial wiring harness |
Ordinary wiring harness |
|
Application scenarios |
In fields such as machinery, power, and medical care, customized and complex requirements are met, and non-standard products are predominant |
In the field of consumer electronics, standard products are predominant |
|
Current and Voltage |
Used in high-current scenarios (such as hundreds of amperes) |
For low-current scenarios (such as a few amperes) |
|
Technology and Structure |
It is made by weaving multiple strands of fine wires into bundles, with a complex structure |
It adopts single-strand thick wires and has a simple structure |
|
Protective and durable properties |
High-temperature resistant, wear-resistant, waterproof and dustproof |
It has relatively low requirements for environmental adaptability |
|
Standards and Certifications |
Complies with strict safety certifications |
It only complies with the standards of the basic electronics industry |
Frequently Asked Questions
What types of industrial wiring harnesses are there?
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Industrial wiring harnesses are fundamental equipment for various machines, devices and instruments to achieve power and signal transmission. They are indispensable basic products in an electrified society. The products of industrial wiring harnesses are roughly classified into four aspects based on their functions. According to the application scenarios, cables with different functions are selected for combination and use. Specifically, the following table introduces power wiring harnesses, control wiring harnesses, signal wiring harnesses, data wiring harnesses, etc.
Industrial wiring harnesses are classified by function
1. Power supply harness. Wiring harnesses that can transmit electricity, such as the power cord of an air conditioner switch, the wiring harness connecting a mobile phone battery, and the power cord of a computer, etc.
2. Control the wiring harness. It is mainly used to connect circuit boards to control electrical signals and to connect wire harnesses of different control components, involving switches, relays and other parts.
3. Signal wiring harness. Wire harnesses for transmitting signals, such as low-voltage signals, control systems, and sensor signal transmission.
4. Data wiring harness. Data transmission harnesses are generally used in communication and computer equipment to upload and download signals, such as HDMI, USB, etc.
What is the impact of industrial wiring harnesses on daily life?
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Industrial wiring harnesses can affect the transmission of signals and energy, the use of machinery in manufacturing workshops, the application of medical imaging equipment, and the control of high-speed rail systems. The fine copper conductors in the wiring harnesses precisely coordinate the 0.01-millimeter-level operational accuracy of mechanical equipment.
1.In the network, production instructions at the Megabyte level are transmitted at the speed of light.
2. In an aero-engine, data from tens of thousands of sensors are transmitted within it.
3. In the processing of precision machine tools, the transmission of signals enables the service system to improve processing accuracy more rapidly.
According to a study by the International Electrotechnical Commission, industrial wiring harness jobs failures have accounted for 37% of downtime accidents in intelligent manufacturing systems, and this figure has risen to 52% in unmanned factories. The accidents caused by the failure of industrial wiring harnesses will have a chain reaction. The failure of the power grid control system will plunge the city into darkness and make it impossible to use household appliances. The production halt of car manufacturers will cause supply chain disruptions, and the interruption of medical equipment usage will threaten patients with diseases and bring inconvenience to daily medical care.
What is a wiring harness assembly?
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A wire harness assembly refers to a complete connection system formed by arranging different wires together and equipped with corresponding terminals, connectors and other accessories, which connects various electrical facilities to ensure the transmission of current and signals.
How to choose industrial wiring harnesses?
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When choosing industrial wiring harnesses, the following key factors are mainly considered:
1. Application environment: Select the corresponding wire material and type based on the different application environments of the wire harness. For instance, automotive wiring harnesses need to have the characteristics of high-temperature resistance and oil resistance, while energy storage wiring harnesses only need to meet the specified current rating and temperature resistance.
2. Electrical performance: Clearly define the voltage and signal transmission requirements that the wiring harness can meet. Especially for high-voltage wiring harnesses, attention should be paid to their current-carrying capacity and withstand voltage level.
3. Safety: Industrial wiring harnesses must strictly comply with safety standards such as ROHS, ISO9001, UL, REACH, etc.
4. Durability and reliability: Select wires that can be used for a long time under extremely harsh conditions, such as high-temperature resistant, wear-resistant, and oil-resistant conductors and sheaths.
5. Connectors and terminals: Select connectors and terminals suitable for the application scenario to ensure continuous conductivity and mechanical strength during operation.
Final Thoughts
This is our introduction to industrial wiring harnesses. By understanding the classification and application of industrial wiring harnesses, you can quickly know what kind of industrial wiring harness you need. Through our series of industrial wiring harness options, you will find everything about the industrial wiring harness you need. We always support you via email (sales003@ecocables.cn) and phone (Mobile: +8613412331588).