What goes into making a flawless wire harness?

Have you ever wondered what it takes to turn a complex design into a reliable component that powers everything from cars to aircraft? Is it just about connecting wires and terminals, or is there something more at play?

The reality is that building a wire harness isn’t just about following a blueprint; it’s an orchestrated symphony of precision, planning, and flawless execution. Every step in the process, from design to shipping, is critical to ensuring that the final product performs flawlessly under the toughest conditions, where every detail matters, and excellence is the only option.

Overview of wire harness manufacturing process

Design and engineering phase

• Initial design considerations: The process starts with gathering detailed specifications from the client, including electrical requirements, environmental conditions, and spatial constraints. Engineers use this information to develop a schematic or wiring diagram that outlines the electrical connections and physical layout.
• Component selection: Based on the design requirements, specific types of wires (e.g., gauge, insulation material), connectors, terminals, and protective sleeving are selected for their suitability in terms of electrical characteristics, durability, and compliance with industry standards.
• Software tools: Advanced CAD (Computer-Aided Design) and electrical design software are employed to simulate the wire harness's performance, optimize the layout, and create detailed manufacturing drawings and instructions. This step is critical for identifying potential issues before production begins.

Material procurement

• Supplier selection: Choosing reputable suppliers for high-quality materials is essential. The procurement process includes evaluating suppliers based on their ability to meet quality, quantity, and delivery time requirements.
• Inventory management: Effective inventory management strategies are implemented to ensure a steady supply of materials while minimizing excess stock and associated costs.

Wire cutting and stripping

• Automated processing equipment: For high-volume production, automated wire cutting and stripping machines are used to ensure precise and consistent preparation of wires. These machines can be programmed to cut wires to exact lengths and strip insulation without damaging the conductor.
• Quality checks: Post-cutting and stripping, wires are inspected for correct length and proper stripping, ensuring that no nicks or damage have occurred to the wire conductor.

Assembly

• Crimping and connection: Terminals are crimped onto wire ends using either manual crimping tools or automated machines, ensuring a secure and conductive connection. Operators must follow specific crimping specifications to avoid loose connections or damaged conductors.
• Routing and bundling: Wires are then routed according to the design layout and bundled together using cable ties, tapes, or sleeving. This step requires careful attention to prevent stress or damage to the wires and to maintain the design's organizational scheme.
• SolderingSoldering standards: Where soldering is required, it is performed in accordance with industry standards (e.g., IPC J-STD-001) to ensure high-quality solder joints. Operators trained in soldering techniques use appropriate solder and flux to achieve a strong, conductive bond while preventing overheating or damage to components.

Testing

• Electrical testing: Comprehensive testing is conducted on each wire harness to ensure it meets all electrical performance criteria. This includes continuity tests to verify there are no breaks in the circuit, insulation resistance tests to ensure the integrity of the insulation, and functionality tests if specific signals or power levels must be confirmed.

Inspection and quality control

• Visual and manual inspection: In addition to electrical testing, each wire harness undergoes a thorough visual and manual inspection to check for any physical defects, incorrect wiring, or non-compliance with the design specifications.
• Documentation and traceability: Quality control processes include documenting inspections and tests, maintaining records for traceability, and implementing corrective actions for any identified issues.

Packaging and shipping

• Protective packaging: Completed wire harnesses are carefully packaged to prevent damage during handling and transport. The choice of packaging materials and methods depends on the size, shape, and sensitivity of the wire harness.
• Shipping logistics: Efficient shipping arrangements are made to ensure timely delivery to the client or next assembly point, with considerations for tracking and protecting the cargo during transit.

So, how do all these steps ensure the final product performs flawlessly under the toughest conditions? The answer lies in understanding that each stage, from design to shipping, is a critical link in a chain that must be meticulously managed to produce a superior wire harness. At Cableteque, we built PIA to guide and support engineers throughout the entire process because 70% of initial designs contain avoidable errors.

About Cableteque

Cableteque’s Predictive Interconnect Analytics (PIA) software is a cloud-based AI solution that helps increase efficiency and reduce mistakes by automating the identification of failures and creating a foolproof digital twin to transfer knowledge during the development process. The software allows data synchronization with multiple databases and proprietary design rule checks (DRC) to minimize costly mistakes in the early stages of product modeling and design. PIA integrates seamlessly with CAD tools and provides comprehensive feedback to help designers target “design risks” and enhance confidence in the expected outcome. Cableteque’s PIA software is an add-on tool to the designers’ CAD, and it will integrate seamlessly with numerous native CAD tools by leveraging standard outputs of design tools such as the parts list, From-To lists, and other design data and provide comprehensive feedback so that the designer can target “design risks” to minimize mistakes and enhance confidence in the expected outcome.

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.