The word “wire harness” refers to an assembly of cables and wire harnesses that are used in many different applications to transmit power and signals. The cables are bundled using a sturdy and trustworthy material such as electrical tape, vinyl, etc. Cars, heavy machinery, flat panel displays, and many other things all need wire harnesses. Wire harness manufacturers in Gujarat make wire harnesses with processes that vary based on the designs and needs of the task. The need for wire harnesses is increasing, so it’s critical to understand the entire wire harness production process. This article provides further information on this procedure.

Design

The creation of a suitable design is the first step in the wire harness production process, just like in any other electronics manufacturing process. They can be found anywhere, such as in the panel of industrial machinery, the washing machine, or beneath the glove box of an automobile. They provide power and data in an efficient manner. These applications would have different designs. Thus, one of the difficult parts of the wire harness manufacturing process is coming up with a particular design. 

During this phase, the design engineers must also take care of any performance problems that the wire harnesses might have when operating normally. They also have to choose components, materials, and other issues in addition to fixing components.

Prototyping

An engineer or product designer can test a real-world version of their final product if needed with wire harness prototyping. After that, they may ensure peak performance by testing the harness in the target application before starting the first production run.

Production and Assembly

High-quality standards with low error rates must be maintained in the fabrication of wire harnesses, and design specifications must be fulfilled. Surprisingly, wire harness production procedures still heavily rely on physical assembly in this day and age, despite automated manufacturing growing significantly in almost every industry. 

The process of making wire harnesses and cable assemblies by hand is required since there are numerous complex and time-consuming procedures that must be completed, even though some automation can be included. Although constructing a wire harness can be challenging and task-oriented, hand production is still more economical.

Wire Cutting

Generally speaking, the first step in constructing a wire harness is to ensure that the wires are precisely cut to the desired length using a wire-cutting machine.

Stripping & Connections

To reveal the cores, the wire ends must be removed in the following step. In order to attach terminals, connector housings, or modules later, this is done.

Assembly

Finally, in order to comply with the design standards, the wires are assembled into a harness using a workbench or assembly board. In order to route wires through sleeves and apply fabric tape where necessary—for example, on branch outs from wire strands—hand manufacture of wire harness fabrication is required. Terminals must be crimped onto wires; additional crimping will be required if more than one wire needs to be connected to a single terminal. In addition, all sleeve insertions and strand fastenings using tape, clamps, or cable ties are done by hand.

Testing

Every electronics manufacturing project must include safety testing. The wire harnesses undergo extensive testing during this phase to ensure their usefulness and durability in actual settings.

Conclusion

It’s important to work with reputable wire harness manufacturers in India like Jayshree Instruments if you need custom wire harnesses for your application. The company offers custom-specified wire harnesses to satisfy your application needs. Additionally, it specialises in the assembly and fabrication of custom printed circuit boards which is why it has a huge client base across India.