Wire Harness Assembly: How Does It Work?

There are wire bindings all around you. From the ones running inside your computer or television set, to under the hood of your car. To put it in its most basic terms, a circuit of wires is a collection of cables or wires attached in specific ways to transmit electrical signals and powers.

If you have ever wondered how a cable assembly works, you have come to the right place! Here is your guide to assemblies in production and operation.


A cable feature is engineered according to the spatial-geometric and electrical requirements of the product. The result is a technical diagram to guide the set-up and assembly of the circuit by the production technician, who will usually receive some training on the exact assembly process.

Once the technician has selected the raw materials specified by the plans, he or she will cut them to the desired length, using a special stripping and cutting tool. With the wires cut and the metal core exposed at the ends, they are fitted into terminals or connectors. Often the ends of the wires will be inserted into an assembly board according to a specific layout, and then will be covered with a protective sleeve to form the harness.

Although technology in this industry has advanced greatly, much of the manufacturing is still being completed by hand. This is largely due to the variety of processes involved and the difficulty of automating those processes. Producing harnesses by hand is far more cost-effective than automation would be, particularly since many orders are custom-made and in small or varied batch sizes.


The actual working of a wire cable manufacturer is relatively simple. Within each wire is a conductive material, usually copper or a blend of copper and aluminum or tin, which transmits electrical power, or information in the form of an electrical signal. This wire is then covered with insulation to protect it from heat and the elements, shielding to prevent signal loss and interference, and jacketing to protect it from moisture.

Complex electronics like computers and automotive systems have many different electrical functions or programs, so each wire in an assembly often has a different purpose. Yet, letting a bunch of wires run loose around an engine compartment would be a bad idea.

Instead, they are bound together and attached to scaffolding running throughout the engine compartment, or case body in the case of electronic products. This ensures the wiring is non-intrusive and avoids any unnecessary shocks, vibrations, or heat.


This assembly comes in various options today as per their different areas of application. Read on to know more about them as well as how to use them in your area of operation for optimal benefit.

Wiring harness as the name indicates is a string of cables and wires that are used to tie down the informational signals or operating currents to transmit it to their destination. They are nowadays used in the electrical, electronics as well as the automotive industries. In this article, we would deal with them individually.


Automotive wiring parts have made the use of electrical components in automobiles a breeze today. And the technology has reached amazing strides in the last few years.

In fact, the wiring in automobiles industry has become a lucrative industry in itself. This feature is used in different types of electrical wires and components for producing, storing and distributing electrical current to other parts of the vehicle. Among its different functions are starting the engine; providing electrical energy for operating lights; for running air conditioners, dashboard clusters, fuel tank collection pieces wire connections to horns, music systems, and other devices. Apart from these standard uses, there are also varieties of customized solutions of these as well as power supply cord that offer other functions.


This variety is used extensively in all types of electronic gadgets. There are those that are made for computers as computer cables and data for effective data transfer. Then there are harness solutions for a flip flop and toggle applications. Control cable assemblies are used widely in the home appliances industry as well. Audio and television wiring assembly is also one of its many uses today.


The harness itself, is used most highly in the electrical industry. They are used in wiring in residential as well as commercial buildings. Then there are those that are made to supply electrical energy to control panels in various kinds of pumps, telecom components, and textile machines. Power joints connect cables of higher current rating from one machine part to the other. XLPE, HR cables are used for high current applications. Among the many other varieties of electrical components available are an electrical fuse, switches, fuse holders, wiring connectors, switch panels, and relay connectors.


An online source is a great option for ordering the equipment. This is because here you can get access to a many reputed and established manufacturer and exporter of quality international quality products and customer specifications. You can also avail competitive prices that are prevalent in the world market while ordering other electrical items like power supply cord etc. however, before ordering products from the net, make sure that the company follows ISO 9001:2000 standards to ensure that quality products.


A wiring and cabling system is used in all types of industries. There are many machines which are used and are interlinked. The cables are often bound with the help of materials which provide insulation. This process is called wire harnessing. This procedure is applied in several machines such as heaters, air conditioners, and cars. The cables are tied together by tapes or conduit. The loose wires of the different machines are brought together to make the place systematic. If the collection of wires are stretched, it can stretch to a couple of kilometers. It is done for shrinking the space requirement for the wiring systems.


The concept of the custom wiring harness is also called cable materials. When you bind a bunch of wires, you get many advantages. Moisture is the single biggest problem in cable connection. If moisture enters cables, they may not function properly causing short circuits. By bundling the wires up and putting a protective covering, the wires are protected against any moisture attack. Other factors like vibrations and frictions and also nullified by way of wire clamps. The protective layer makes the cables durable and provides a shield against any external harm. The type of protection you require can easily be decoded by customization to suit your working area.

Post time: Dec-14-2018