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Wire harness assemblies transmit signals or electrical power within complex electrical systems. When designed and assembled correctly, they enhance the safety and efficiency of the overall system. PGF Technology uses state-of-the-art automation technology to produce high-quality wire harness assemblies for various applications, including automotive, aerospace, computer, biotechnology systems, EV applications, and many other applications.

 

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A wire harness assembly integrates wires, cables, or subassemblies packaged within a durable exterior sleeve. Typically made from thermoplastic or thermoset materials, the sleeve keeps the wires organized and protects them from the surrounding environment. The wires—usually made from aluminum or copper—transit the information or electricity required to operate the electrical system. While cable assemblies generally have two ends, wire harness assemblies feature several branches with multiple terminations per branch.

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Most wire harnesses are designed with a specific application or device in mind for optimal functionality and safety. The most important factors to consider during the design process are space requirements, installation preferences, and power demands of the equipment or device in which the harness will be used. Other factors to consider include temperature, chemical exposure, humidity, flexibility, and color preferences. In general, the length of time required to manufacture the wire harness assembly will depend on the design’s complexity.

Given the complexity of wire harness assembly manufacturing, working with a provider with the relevant design and manufacturing experience is essential to meet your specific requirements. Creating a wire harness assembly typically involves the following key steps.

 

 

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Once the customer and manufacturer establish the geometric and electrical requirements, a detailed schematic ensures that the assembler follows all design and electrical guidelines throughout the production process. This process involves creating an assembly board, which provides a full-size diagram of the wire harness and the proper location of its wires and components. The wire harness assembly board also provides a workbench for assembling and clamping the wires together.

 

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Suppliers provide the wires required for the assembly in a master reel. Each wire is carefully measured, marked, and cut to the appropriate length. If needed, individual wires within the assembly can be identified using labels or barcodes.

 

 

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The ends of the cut wires are then stripped and fitted with the appropriate terminals. Wire terminals are responsible for establishing the required connection for the application. Typically, manufacturers add terminals by crimping them onto one or both exposed wire ends using an automated or manual crimper.

 

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The wires and subassemblies are arranged and installed on the assembly board and routed through any necessary connector housings or conduits. Team members then bundle all components and wires together using sleeves, wraps, ties, tapes, or combinations.

 

 

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Once the wire harness assembly is complete, post-production testers verify the final product’s electrical functionality and safety. In addition to visual inspection, this process utilizes digital test boards to look for defects. Quality inspectors evaluate the unit’s durability under the relevant environmental conditions. The assembler then performs any final operations to prepare the harness for packaging and shipment.

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Wire harness assemblies provide the following benefits when designed, constructed, and installed correctly.

cost benefits of a wire harness assembly

Cost savings: Wire harness assembly methods are one of the most cost-effective solutions for keeping wires organized within an electrical system. Design and material requirements for wire harness assemblies tend to be more complex than those of two-ended cable assemblies. This distinction allows the harnesses to manage multiple applications at once, saving the cost and space that would otherwise require cable assemblies.

fast installation of a wire harness assembly

Fast installation: By integrating all wires, cables, and subassemblies into a single, compact unit, wire harnesses help streamline the production of larger systems. They provide fast and simple drop-in installation, eliminating the time-consuming running of all wires and cables individually.

security and safety of a wire harness assembly

Increased security and safety: Securing wires within a single bundle provides greater protection against abrasion, vibration, moisture, and electrical shorts. Various customization options provide different levels of protection. For instance, flame-retardant sleeves also reduce the risk of an electrical fire.

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With their cost- and space-saving benefits, wire harness assembly processes have become a valuable part of the consumer, commercial, and industrial electrical devices and systems. Examples include:

  • Electronics: In electronic devices, wire harness assemblies are responsible for supplying power and transmitting data required for operation. Their uses include personal computers, laptops, diagnostic medical devices, machinery, and more.
  • Automotive: Wire harnesses provide vehicle manufacturers with an affordable and efficient way to keep individual wires, cables, and subassemblies conveniently grouped in a single unit. In practice, teams embed these units in the vehicle’s engine, chassis, and body to transmit signals and deliver power.
  • Construction machinery and industrial equipment: Durable wire harness assemblies are critical for operating heavy construction and industrial equipment operation. They ensure reliable transmission of electrical signals while keeping wires protected from abrasion, impact, and vibration.
  • Household appliances: Wire harness assemblies enhance the safety and reliability of household devices such as washing machines, dryers, dishwashers, and refrigerators.

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Download our eBook, Key Considerations for Medical PCB Assembly or  The Shortcut to Success: A Road Map to PCBA Prototypes for overviews of the important considerations for assemblies!

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PGF Technology is a full-service provider of reliable and cost-effective wire and cable solutions for a range of household, commercial, and industrial applications. Our wire harness assembly equipment can customize solutions to meet each customer’s unique specifications to ensure optimal performance. Our services include:

  • Design and testing support
  • Fabrication
  • Prototyping and product development
  • Turnkey component assembly

Importantly, our in-house Wire Processing Center allows for accurate and replicable assemblies.

Overall, we maintain strict compliance with ISO 9001:2015 and ISO 13485:2016 standards, and our employees undergo thorough training programs centered around IPC 620 Class 2 & 3 standards. We evaluate every product using the latest wire and cable harness assembly testing technologies, including:

  • Multi-Unit Easy Touch HiPot Cable Testers
  • Multi-Unit Signature 5000 and 1000 Testers
  • High Voltage Hi-Pot Testing Capabilities

These qualifications and capabilities allow us to deliver high-quality, industry-compliant wire harness assemblies for some of the most demanding electrical applications. Please contact us today or request a quote to learn more about our wire and cable solutions.

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