Every Possible Issue Related To Wire Harness – The Problems & Solutions – Miracle Electronics
Wire harnesses are engineered for different applications, but they play a critical role mainly in electrical and electronic devices and systems. Their rugged construction helps them to withstand almost all kinds of impacts and environments such as extreme temperature, humidity, compression, friction, vibration, etc.
However, these harnesses can experience certain issues that can stop them from working as expected. Below, we’ve highlighted some of the most common problems that occur, along with some ways to either avoid the issues or resolve them.
Common issues
While there could be multiple kinds of problems seen within a wire harness, the most common issues include –
- Poor performance
- Shorter lifespan
- Incorrectly placed components
- Missing components or wires
- Oxidation
- Corrosion
- Circuit issues
The causes
Inappropriate material selection – If the material chosen to build the harness is not one that can withstand the environmental forces in which it is to be installed, it can lead to poor quality and deteriorated performance.
Incorrect wire preparation – Not only is selecting the material important; it’s also vital that the wire is cut to the right length, stripped right , and connected correctly. Failing to do so can lead to incorrectly prepared components.
Incorrect installation – Any imperfections in installing the wires can result in imbalanced pressure, circuit issues, and deterioration in the quality and performance over time.
Inadequate/flawed testing – If the harnesses are not tested properly, it may lead to missed issues that may cause bigger problems in the future.
Incomplete protection – Oxidation and corrosion are quite common to occur when certain metals come in contact with air and moisture.
The solution
It is very important to test the harnesses in order to eliminate all the above issues. Testing them after completion of every manufacturing stage, as well as after completion of the entire process, is essential. This brings forward any issues immediately so that the problem can be resolved at the earliest before moving on to the next stage. This results in reduced wastage of time, material, and labour. There are five different ways in which the harnesses can be tested.
Visual testing – This involves visually analyzing if every component is placed correctly or not; for instance, the dimensions, the gauge, the placement, the connectors/terminals (), and the labelling.
Mechanical testing – This involves testing the mechanical properties such as flexibility, tensile strength, elongation, impact resistance, and crush resistance.
Electrical testing – This involves assessing the electrical performance; whether or not the configuration and performance are proper or not. Open wires, incorrect wiring, and shorts are tested for, by connecting the harness to an electrical fixture.
Environmental testing – This involves testing whether the harness can withstand the environmental conditions it is installed in, such as humidity, temperature, pressure, and vibration.
Signal integrity testing – This involves assessing the strength of the signals that can be carried, which include signal error and crosstalk. Whether or not the signal strength can be maintained with the integration of connectors, filters, or splices is also checked for.
Partnering with Miracle Electronics
You can see how it is important that you partner with a professional wire harness manufacturer like Miracle Electronics, where the harnesses are not only manufactured, but also tested at every stage to identify for potential errors at the earliest, so as to reduce wastage of time and labour, and bring to the client a thoroughly tested end product.
