Wire Harnesses & Cable Assemblies – The Manufacturing - Miracle Electronics

When you want to build an electrical system, you’ll need lots of wires and cables, which makes it better to replace them with fewer harnesses or assemblies. Wire harnesses or cable assemblies will hold multiple wires together, optimizing space, as well as protecting the wires against climatic and environmental conditions like heat, moisture, vibration, etc. Thus, errors and faults are eliminated, helping the functioning of the system to run smoothly.

Are wire harnesses and cable assemblies the same?

So, when we speak of having wire harnesses or cable assemblies, do you realize the difference between the two? Generally, as a layman, you may consider both of them to be the same, but when you get down into the details, you’ll notice that they are actually two different things. Let’s help you with understanding the differences.

• Wire harnesses involve wires that are individually sealed, and then wrapped in another casing. But, these are not as durable, and are thus used in small electronic applications and internal systems.
• Cable assemblies, on the other hand, are bundles of wires or cables in a single heavy casing. This equipment can be easily used in harsh environments because of the heavy-duty thermoplastic rubber or vinyl used for the casing, which helps hold up against outside elements like extreme temperatures, moisture, friction, abrasion, and compression/expansion.

How are harnesses and assemblies made?

• Planning – The first and foremost step is planning, both the design and construction. Without a pre-plan, no product can be successfully made. In the case of harnesses or assemblies, the type and size of wire needs to be determined, to be used between each connection.
• Prototyping – A test version is first created depending upon the plan. It helps engineers know how the final product will look like, while identifying any errors or gaps that need to be rectified before building the actual product.
• Wire cutting – Once the prototype is approved, it’s time to move on to the actual product making, which involves first cutting the wires to the required length. Wire-cutting machines can be used here to automatically cut the required wires in bulk.
• Wire stripping – After cutting, the casing is stripped back to reveal the core, which is then fed into the necessary connectors. Crimping and soldering the wires into their proper connections can be automated with the help of machines.
• Assembling – The prepared wire-connector devices are gathered up and crafted into a harness, which is done majorly with the help of manual labour. This is because each wire needs to be fed through the harness, taped off, and measured to make sure that the distances match the design specifications.

Partnering with the right manufacturer

Manufacturing harnesses and assemblies is a time-consuming task, especially because of the intensive manual labour required in the last stage of assembling the equipment together. And, in order to not waste any more time, you need to get hold of a manufacturer who knows the job well so that there is no time wasted in making errors and rectifying them. Moreover, the manufacturer you should must have the right machines to make the process as automated as possible, and the right tools to use to speed up the processes that require manual labour invested. Some of the most basic tools that a good manufacturer must have are an injection mould machine, wire cutter, wire stripper, crimper, positioners, die sets, insertion and extraction tools, and all sorts of testers for testing the assemblies before delivering them to the customers.

Miracle Electronics is one of the best cable harness manufacturers in India you can approach to have your harnesses and assemblies made, as they have the right tools and machineries, skilled engineers, and the best testing facilities to build and test your products. Moreover, they are also skilled at manufacturing customized wire harnesses and cable assemblies  if you wish, each product being certified and approved by DGAQA and MSQAA for platform specific applications.