How to design EWH for all environments

Are your wire harness designs fully protected against all types of environmental threats? Environmental protection is not just an afterthought; it's an important aspect that can dictate the reliability and longevity of the system. But how can you ensure that your designs are free from errors and robust against such conditions? Automation and validation software may hold the key.

The impact of early detection - a reminder

1. Cost and time efficiency: Detecting these errors early in the design phase with automation software drastically reduces the cost and time required for rework. It's a proactive approach that ensures reliability and eliminates the need for costly late-stage modifications.
2. Quality assurance and longevity: By adhering to industry standards through automated checks, manufacturers can assure the quality and compliance of their wire harnesses, thus avoiding the repercussions of product recalls or failures in the field.

Environmental protection: The crux of EWH design

• The challenge: Wire harnesses are the nervous system of any electrical assembly, be it in a car, plane, or medical device. They must withstand a barrage of environmental factors: temperature fluctuations, moisture, chemical exposure, UV, and mechanical stress, to name a few. When not accounted for, these factors can lead to catastrophic system failures.
• The solution: Automated software solutions are revolutionizing the way engineers approach environmental protection in EWH design. These tools can preemptively identify potential errors that could compromise the harness's integrity under environmental stressors.

Specific error types to watch out for

Inadequate sealing and insulation

• Error type: A common error in EWH design is underestimating the need for proper sealing and insulation. This oversight can result in moisture ingress and chemical corrosion, leading to short circuits and degradation of wire integrity.
• Fix: The right software can simulate various environmental conditions, testing the harness design virtually. It checks for adequate sealing and insulation, ensuring that the materials chosen meet industry standards like AS50881 for aerospace or ISO 26262 for automotive applications.

Incorrect material selection

• Error type: Choosing materials that can't withstand the operating environment for a particular use case can lead to insulation break down and wire exposure.
• Fix: Use validation tools to cross-reference material properties against environmental requirements. They alert designers if materials are unsuitable for the expected temperature range or chemical exposure, guiding them towards better choices.

Inadequate strain relief

• Error type: Without proper strain relief, wires can be subjected to stress that leads to insulation failure and wire breakage.
• Fix: Chose software that evaluates the mechanical design, ensuring that strain relief is incorporated at critical points. It checks for compliance with standards like IEEE 315-1975, which outlines best practices for electrical connectivity and layout.

Faulty shielding practices

• Error type: Inadequate shielding can leave wires vulnerable to electromagnetic interference (EMI), which can disrupt signal integrity.
• Fix: Use automated tools that analyze the shielding design, verifying that it meets the necessary EMI protection levels. This includes assessing the coverage, continuity, and grounding practices.

Bonus: End-of-Life Management

Design for disassembly and recycling

Cables and wire harnesses should be designed to facilitate easy disassembly and recycling at the end of their life cycle. This includes using connectors and materials that can be easily separated and processed for recycling.

Take-back programs

Manufacturers should consider implementing take-back programs to ensure that end-of-life products are disposed of responsibly and do not end up in landfills.

The margin for error is slim. Automated software solutions provide a safety net, catching errors that could otherwise slip through the cracks of manual inspection. As we integrate more sophisticated electronics into every aspect of technology, the role of automation ensures wire and cable harness designs survive any type of environment with longevity.

About Mr Arik Vrobel

For over 30 transformative years, Arik led the evolution of El-Com Systems into a pinnacle of excellence in Electric Wire Harnesses (EWH) for global enterprises. In his final 5 years, he steered El-Com to become the foremost provider of engineered harnesses for the commercial-space sector, supporting groundbreaking projects on space platforms.

Since its acquisition by Winchester Interconnect, driven by his entrepreneurial spirit, Arik founded Cableteque, a beacon of innovation offering AI-based CAD tools to enhance and validate engineering designs of EWH, inspiring the industry with his vision for impactful technological advancement.