You have a need. by Donnie Hill | Apr 15, 2020 | Wire Harnesses | 0 comments. We also have a staff of engineers who can answer your questions on wire harnesses and offer recommendations on how best to design them. Key Points of the Manufacturing Process to Build Your Wire Harness. ©2017 Precision Manufacturing Company Inc. All rights reserved. Today, approximately 85% of all wire harness manufacturing operations are carried out manually. Wire harness manufacturing continues to be an extremely labor-intensive process. Including quality assurance, signal integrity analysis, environmental analysis, and custom designs. The same goes for torque values on fasteners, in which you should also use the manufacturer’s recommended values. Input: What Your CM Needs for the Wire Harness Manufacturing Process Contract manufacturers often build both cable assemblies and wire harnesses. This ensures that only the highest quality harnesses leave our facility Next, the ends of the wires are stripped to expose the uninsulated conductor and fitted with any required terminals or connector housings. Our mission at Wise Harness Solutions is to continually strive to improve our products and service to meet and exceed our customers’ expectations and requirements. Standardization is the core component of lean manufacturing. What Are the IPC Component Spacing Guidelines. This includes all possible variants of the wire harness, based on all possible options for a … First off, your CM will examine your bill of materials and other documentation to make sure that everything they need is in place. 6190 San Ignacio Ave. Variosystems wire harness production video Sri Lanka. in the wire harness manufacturing process. These benef… The engineers at the wire harness manufacturer use this drawing to create a production drawing, a work plan and corresponding parts lists. Then, the harness is meticulously laid out, just as we demonstrated to the kids how to execute the play. The manufacturing process for wire harnesses can go from basic to very complex. During this phase, each harness has its electrical connections tested using sophisticated computer software. This process ensures that the harness was constructed properly. Your email address will not be published. The first step in the manufacturing process is to discover the problem that the wire harness or cable assembly is meant to solve. To distinguish between the two, a cable assembly is an external connection to devices and will have different environmental considerations, such as their thickness, insulation type, and flexibility. However, as with anything that is manufactured, the more. Despite the product names, both cables and wires may be found within wire harnesses and cable assemblies. However, as with anything that is manufactured, the more detailed documentation and precise specifications you can provide, the fewer problems there will be on the assembly floor. Fully automatic block loading and wire harness manufacturing will become increasingly important in the future. We manufacture to the IPC/WHMA-A-620 quality standard.. Leveraging Digitalization in Wire Harness Manufacturing. Quality standards are very high, particularly in the heavy transportation and off road vehicle and equipment sectors, with minimal error rates allowable. The component manufacturer usually provides termination recommendations for how the wires should be attached. Today, as I work with wire harnesses that are built for electronic devices, I am reminded of those days coaching the kids on how to put the play together. Building on 30 years of experience, enterprise-wide software, and management commitment—we have the answers to your PCB challenges. There is one thing that stands out in my mind, however, and that was when a play worked the way we designed it. The design includes all possible variants of the wire harness, based on all possible options for a particular vehicle model. After this, the ends of the wires are then stripped to expose the core of the wires. Car companies have started to take interest in using This gives the CM the flexibility to use what works best for the harness requirements that is also readily available and cost the least. Wire harness assemblies are often confused with cable harness assembly. In a nutshell, a wire harness assembly is the binding process of wires, terminations, and connectors within insulated materials. The very first step in assembling a wire harness is to cut the wires to the desired length, usually done by a special wire-cutting machine. The process starts with design and development of the wire harness. Our wire harnesses are offered as a turnkey solution, which includes every process from conception through installation. Additionally, the assembly panel will be created with all the necessary pegs set at the specified locations. Now, the harness will be built. When it finally came together in a game, it was a beautiful thing to see. This article presents the ultimate guide to wire harness manufacturing. Wire harnesses offer a range of benefits, such as: Wire harnesses are used in far too many applications to list here, but here are some specific examples of notable use cases for wire harnesses: These examples only make up a tiny fraction of relevant use cases for wire harnesses, which see extremely broad usage across major industries such as appliances, construction, heavy and industrial equipment, electronics, military and defense, medical equipment, and many others. Part 2 will continue this discussion and demonstrate the benefits of digitalization and MBSE for wire harness manufacturers. The process starts with design and development of the wire harness. We also have a. who can answer your questions on wire harnesses and offer recommendations on how best to design them. What is a Wire Harness Manufacturer? Finally, the cables or wires are bound with an outer covering using an assembly board, which guides proper breakouts and allows for final electrical testing. These harnesses are important because they organize wires for easy implementation into equipment and systems. Cut to your company’s specifications. Tubing, Loom, Heat Shrink, Wire and more. You should know more to make the right choice. Crimping wires as part of the wire harness manufacturing process may seem like a no-brainer step where any crimp will do. The vehicle manufacturer provides a 150-percent-drawing of the design of his on-board wiring system to the wire harness manufacturer. Manual assembly is still the most common method for wire harness manufacturing because routing cables or wires through sleeves is an extremely delicate process. Lapp Tannehill offers the Wire Harness Manufacturing industry decades of experience in cabling and wire harness solutions, having served over 450 wire harness manufacturers. If needed, the wires will then be inserted into a connector housing, allowing the mating of male and female bundles of wires. We understand that standards are extremely important to wire harness manufacturing and OEM’s. We can process many different materials cut to length. The next step usually involves wire cutting, stripping, and terminating. Usually, you specify these dimensions, and contract manufacturers are used to getting a wide range of information to work with. We first diagramed the play out for the kids, and then we practiced it until they understood the moves. A Wire Harness Manufacturer is a company or business that provides services to complete the wire harness assembly process. Today, approximately 85% of all wire harness manufacturing operations are carried out manually. Manual operations for wire harness assembly include: At Precision Manufacturing Company, Inc. (PMCI), we work with clients from wire harness design and schematic development into prototyping and production. Wire harness manufacturing continues to be an extremely labor-intensive process (Figure 2). and precise specifications you can provide, the fewer problems there will be on the assembly floor. This way, the harness is laid out to the exact dimensions that are required. Our wire harness assembly services include: Please contact us or request a quote for more information about our wire harness options and capabilities. They will also evaluate your specified parts to see if those are the best choices due to cost. If you take your time, you will find the process to be less demanding. Coaching children’s recreational league basketball when my kids were growing up was very rewarding—even if it was more like herding cats than playing actual basketball. Here is a sampling of the data that will best help your contract manufacturer when building your wire harness: With the documentation in hand, you should expect your contract manufacturer to follow a general process in building your wire harness: The building of your wire harness is a pretty straightforward operation, but there are some details you should be aware of to help to speed the assembly through manufacturing. Harness Manufacturing Software. Some types of terminals include ring, tongue, spade, flag, hook, blade, quick-connect, offset and flagged. Contract manufacturers often build both cable assemblies and wire harnesses. Once the bill of materials is finalized, the CM will next purchase the components and materials needed for production and test of the harness. A wire harness must also be manufactured with a terminal, defined as "a device designed to terminate a conductor that is to be affixed to a post, stud, chassis, another tongue, etc., to establish an electrical connection." The next step usually involves wire cutting, stripping, and terminating. The wires are stripped and cut at the right length and metal terminals are attached to the ends of the wires all using a specialized machine commonly known as a crimp center. We strive to provide the highest quality wire harness and cable assemblies in the industry. Wire harnesses are bundles of electrical wires that each have their own individual covering but are also bound together using an additional outer covering. This will include detailed assembly steps, images and illustrations, and test procedures. It starts with the design process and making sure that the harness incorporates any necessary custom features for its intended application. In this blog, we will discuss everything you need to know about wire harnesses, including what they are, how they are used, and how they are manufactured. A wire harness is an assembly of wires, cables and connectors that transmit electric power or signals. Wire harnesses typically provide a bunch of cables and wires with some degree of protection and keep them organized, while cable assemblies bind multiple covered wires tightly with a covering to provide robust protection suitable for more demanding environments. We can provide a solution. The manufacturing process for wire harnesses can go from basic to very complex. It keeps the components organized and provides a layer of protection in case of harsh conditions, abrasions or friction. Your email address will not be published. First, the wire harness specifications are drawn up in the same way we would diagram the play. Be sure, then, to use those recommendations—such as stripped and bare or stripped and tinned—as that is what the component is built for. We always encourage our customers to work with us early in the development of a wire harness so we can help you to select the best performing parts. It starts with the design process and making sure that the harness incorporates any necessary custom features for its intended application. Early vehicles, even those with electric propulsion systems, were primarily achievements in mechanical design and engineering. Our process begins with a customer who approaches us with a question and design requirements. As a matter of fact, the common theme in most customer requirements is to reduce … Wire harnesses are laid out and built on a panel that has pegs positioned strategically where the wires will branch out into different directions, or connectors need to be added. Every wire harness is different, however, the basics of wire harness construction is pretty much the same. WHMA is the ONLY trade association exclusively representing the cable & wiring harness manufacturing industry including manufacturers, suppliers and customers. Valley Services Electronics Specific UL-coded wire may not be essential for the harness and instead could turn out to be difficult to find or expensive to use. Wise Harness solutions is a manufacturer of high-quality wire harnesses, control panels, and battery cables for a variety of applications. https://blog.jemelectronics.com/wire-harness-manufacturing-process Arcadia Harness Manufacturing enables Harness Manufacturers to save significant time, avoid duplication of data and minimise errors in their workflow with automatic tools to produce full-scale formboards and generate documentation to give to manufacturing. Here are more details of the wire harness manufacturing process that your contract manufacturer should go through when building your assemblies. Some wires will remain outside of connectors and attached to the original equipment individually. We submit every wire harness to electrical safety testing to ensure it is safe for use. You should also provide generic specifications for wires, such as 300V or 600V, instead of a specific UL code. Every harness is validated 100% for electrical continuity. Standardization provides known cycles and takt times, simplifies training, provides a flexible and multiskilled workforce, creates a visual factory, identifies waste, provides a measurable quality control system, and provides a performance measure for employee reviews and improvements. Wise Harness Solutions utilizes a complete process controlled manufacturing system. Manufacturing wire harness and cable assemblies can be a complex process, but Omega Leads has the experience and knowledge to do it right every time. The wire harness manufacturing process can be challenging given the manual assembly tasks it involves, and the specifications that must be met. To distinguish between the two, a cable assembly is an external connection to devices and will have different environmental considerations, such as their thickness, insulation type, and flexibility. that has been prepared for it to check continuity. Even more troublesome is the fragmentation between the harness design and manufacturing … Connectors will be added, bundles of wires will be tied together, and labels will be attached. The wires needed for the harness are first cut to the desired length and labeled appropriately. The assembly technicians will cut the wire to length, and lay it out on the assembly panel according to the build instructions. The information can be something as simple as a hand-drawn note, or a series of complex 3D CAD models, as well as everything in between. Discussing the Advantages of Multilayer PCB, How to Prevent Solder Bridging During PCB Assembly, How to Maintain Quality Control in Electronics Manufacturing, PCB Defect Detection Strategies for Bare vs. However, the vehicle manufacturer regularly issues … Assembling wire harnesses is a step by step procedure. The final step in the harness manufacturing process is extensive quality control testing. Our cutting equipment can cut with speed and accuracy. Manual production remains the most cost-effective method of assembling wire harnesses because the process of that assembly is too difficult to automate. A … Once a design is established, the process of building a wire harness starts with the development of a schematic that is used to create the manufacturing paperwork and the assembly board for the harness. San Jose, CA 95119, If you are looking for a CM that has the industry experience to build your wire harnesses to the, Input: What Your CM Needs for the Wire Harness Manufacturing Process. Cable Assemblies Manufacturing Process. Wire Harnesses No wire harness project is too difficult for Wise Harness Solutions. At the same time as procurement, the CM will be creating assembly documentation for the manufacturing floor based on your input. Assembled Boards, Rapid PCB Prototyping: Breaking Down the Requirements, PCB Material Properties That Can Impact Board Manufacturability, Six Challenges of Medical Device Product Development, PCB Heat Dissipation Techniques to Protect Your Board. Full assembly drawing with label locations, assembly instructions and tolerances. They may have a protective sheath around the wires that is typically made of thermoset or thermoplastic material, which provides additional protection against damage to the individual wires. Required fields are marked *. The Dos and Don’ts of Having Your Wire Harness Built, , we have been building wire harnesses for our customers for a long time. Optimizing space by grouping wires together, Facilitating customization for specific application needs, Providing extended service life on cables and wires, Availability in a broad range of sizes and lengths, Applying fabric tape in varying locations and amounts, Crimping terminals onto wires, which sometimes requires multiple crimping operations, Fastening strands of clamps, cable ties, or tape, Ultrasonic welding for in-line wire splicing. Below you will find our image gallery from the cable assemblies manufacturing process. Wire harnesses oftentimes get confused for cable assemblies. We always encourage our customers to work with us early in the development of a wire harness so we can help you to select the best performing parts. There’s a lot more to the process of course, and thankfully, the wire harnesses usually don’t talk back to us. 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