A cable harness, also known as a wire harness, wiring assembly, cable assembly or wiring loom, is an assembly of electrical cables or wires which transmit signals or electrical power depending on their function. The cables can be bound together by things like straps, cable ties, electrical tape, conduit, cable lacing, sleeves, a weave of extruded string, or maybe a combination thereof. The industry we are addressing in our wiring production is :
- Electronics and telecommunications industry
- Household appliance industry
- Toys industry
- Moto-Velo industry
- Automotive industry
- The production of industry equipment’s
- Machine tools industry
The first step is cutting the wires to the desired length that is usually done using a special wire-cutting machine. The wires may also be printed on by a special machine during the cutting process or on a separate machine. After this step the next one is to strip the ends of the wires to expose the metal (or core), which then are fitted with any required terminals or connector housings.
The cables are assembled and clamped together on a special workbench, or onto a pin board (assembly board), according to the customer design specification, to form the cable harness. After fitting any protective sleeves, conduit, or extruded yarn, the harness is then properly packed and shipped to customer.
Despite the increasing automation, in general, part of the cable harness manufacturing process continues to be made by hand, the main cause being many different processes involved, such as:
- routing wires through sleeves,
- taping with fabric tape, mainly on branch outs from wire strands,
- crimping terminals onto wires, in particular for so-called multiple crimps (more than one wire into one terminal),
- inserting one sleeve into another,
- fastening strands with tape, cable ties or clamps.
The main priority to BIS is the customer drawings, notes, or specifications but if no customer specifications are called for the default accept / reject will be dictated by the existing manufacturing standards (ISO 9001:2015, IATF 16949:2016).
Examples of wiring configurations:
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