Category: Wire Harness

Wiring harnesses or cable harnesses are vital in many fields of operation where they effectively route electrical signals and power. Because you are probably experts in producing wiring harnesses in India. Your competence covers designing, developing, as well as tailoring these instrumental elements for several reasons. The critical components of wire harnesses play a pivotal role in ensuring the safety, reliability, and functionality of the overall electrical system or device. Let’s delve into the importance of each of these components:

Importance of Wiring Harness and Thoughtful Design: 

Being one of the pioneer harness manufacturers in India, we recognize the immense importance of a well-designed harness. Our offerings are characterized by: 

1. Customization: Wiring harnesses normally require customization about the demands that are Weird to certain applications. For instance, wire lengths, types of connectors, and protective coating material can be subjected to variations to maintain compatibility with the required systems.

2. Quality and Safety: It is important to guarantee the soundness and safety of wiring harnesses. Harness assemblies are an important component that must meet industry standards as well as regulatory requirements to ensure dependability and durability, particularly in such applications as automobiles and aircraft where safety is important.

3. Cost Efficiency: The quality of products does not come at a cost but through proper design and manufacturing processes that entail efficacy. For instance, this is quite imperative for firms that prioritize cost-effectiveness in their industries.

4. Diverse Applications: You stated that wiring harnesses have been utilized in various fields such as automobiles, airplanes, industrial equipment, and electronics. There are diverse demands for each sector which means it has its standard it must follow.

5. Reliability: This is important since the failure of a wiring harness can result in breakdown and dangerous conditions. You must employ rigorous testing and quality control processes for your harnesses to make them trusted.

6. Innovation: The evolution of technological advancement could lead to a rise in the need for intricate and networked power cables and wiring harnesses. It is also important for any company to be familiar with the most recent advances in the field of material sciences and the manufacturing process.

7. Customer Support: Key facet of offering great customer care and after-sales support.

Types of Wire Harness Components:  

Wire harnesses consist of various components, each component serving specific roles in the assembly and functionality of the harness. Here are some  types of wire harness components:

1. Wires and Cables: They are the channels of electrical power and signals. Normally, a wire is only one conductor with no insulation whilst most cables are composed of several insulated wires bunched together with some form of protection for their coating.

2. Connectors: Wires or cables are used for connection of a harness to other devices using connectors. There are different types of them such as plug connectors, socket connectors, and terminals.

3. Terminals: These extensions on the end of wires or cables are known as terminals that connect and provide mounting places for other items. Ring terminals, spade terminals, pin terminals, etc. are some of their versions that differ in size and shape.

4. Sockets: Some examples of these include sockets, which refer to female sockets that mate with pins (male connectors), to electrically connect sockets and pins. They are mostly applied in areas where the replacement of components can be done with ease.

5. Plugs: Males have connectors referred to as plugs, with pins or prongs that penetrate slots forming an electrical circuit with the females, the sockets. They help to connect the harness to different devices of other components.

6. Conduit: In fact, conduit serves as a jacketing or covering of wires and cables; this protects against physical damage, moisture, and other environmental elements, while also providing insulation. Flexible and rigid conduit is determined by application.

7. Sheathing: The harness is completely covered by sheathing or insulating materials, which shield it from any types of external forces like abrasion, heat, chemicals, etc. Some of the common materials include PVC, nylon, and braided sleeves.

8. Tape and Looms: The harness has various connecting mechanisms, including those that bundle and secure wires. Cable looms and electrical tapes are used for organizing wires and preventing their tangling.

9. Grommets: Rubber or plastic grommets protect cables passing through holes or openings on panels or enclosures.

Common Errors to Avoid in Wiring Harness Design: While designing a wiring harness, there are several pitfalls to be aware of:

1. Improper Sizing: Selecting the wrong gauge of wire or inadequate current carrying capability will cause an overheating and electrical collapse. However, an appropriate wire has to be strictly matched with the demands of the system to produce optimal performance as well as safety.

2. Insufficient Protective Measures: If appropriate insulators and protective coverings are not overlooked wires will be exposed to the harmful effects of moisture, chemicals, and damages. Quality insulation is extremely important in ensuring that the wiring harness remains intact at all times, while also avoiding premature breakdown.

3. Flawed Wire Routing: Unplanning of wire loops may lead to unwanted friction, wear, and short circuits. Wire routing must be deliberate if the harness is to stay working and durable.

4. Disregarding Environmental Influences: Wiring harness degrades faster when failures like temperature variations are not considered. The consideration and response towards these environmental issues is necessary to maintain the performance capability of the harness for a long duration.

Wiring harness becomes one of the most essential elements where accuracy and dependability count. Therefore, its combination of wires and parts guarantees that our machines, automobiles, as well as other systems, work properly and securely.

We are a reliable supplier at Elcom International. The factor that makes us unique is our undying commitment to the customer. Elcom International: We are all about the customers and provide bespoke solutions for tailored wire harness needs.

A wire harness, alternatively known as a cable harness or wiring harness, offered by wiring harness manufacturers in India constitutes a structured assembly of wires, cables, and connectors designed to transmit signals or electrical power across diverse applications.

Wire harness solutions find applications across a broad spectrum of industries, including:

Automotive: Wire harnesses play a crucial role in the automotive sector, connecting various electrical components within vehicles such as lights, audio systems, and engine control systems. 

Aerospace: In the aerospace industry, wire harnesses are instrumental in connecting electrical components in aircraft, satellites, and spacecraft.

Electronics: The electronics industry extensively utilizes wire harnesses to interconnect components in electronic devices like computers, televisions, and household appliances. 

Industrial: Wire harnesses offered by harness manufacturers in India are integral in the industrial sector, facilitating the connection of electrical components in machines and heavy equipment such as conveyor systems, robots, and cranes. 

Medical: Within the medical industry, wire harnesses are employed to connect electrical components in medical equipment like X-ray machines, ventilators, and patient monitoring systems. 

Wire harness solutions manufactured by reputable wiring harness manufacturers in India are meticulously designed to meet the specific requirements of each application.

Factors considered include the type and volume of data transmission, the operational environment of the harness, and compliance with applicable regulations governing the product.

Significance of Wiring Harnesses

Now that we have a fundamental understanding of what a wiring harness is, let’s delve into the detailed importance of wiring harnesses.

This exploration will provide a deeper understanding of their purpose and demonstrate how various harnesses provided by different harness manufacturers in India can be applied in diverse scenarios.

 Facilitates Seamless Application:

Wiring without a wire harness solution can lead to a tangled mess. A wiring harness eliminates clutter, providing a centralized source for electrical transmission.

This organized approach simplifies connections, offering a neat and efficient appearance.

Connecting a single group of clamped wires to one source is more straightforward than dealing with numerous wires linked to different slots.

Quality and Durability:

Wiring harnesses support computerized manufacturing processes, minimizing the likelihood of defects. These computerized systems incorporate automatic testing, enhancing overall security.

The inherent robustness of wiring harnesses offered by wiring harness manufacturers significantly reduces the risk of failure.

Such advancements underscore the importance of wiring harnesses in ensuring quality and durability in electrical engineering systems.

Time-Effective Installation:

Constructing a single piece of equipment requires a complex wiring harness solution. Manual installation of individual wires is a laborious task. Integrating all these cables and components into a single apparatus saves significant manufacturing time.

This organized system also minimizes the potential for human error. Time efficiency translates to cost savings, making wiring harnesses crucial in optimizing manufacturing processes and preventing future issues.

Secure Connections:

Systematically bundling wires and cables within a single harness addresses various security concerns. Wires are shielded from moisture or abrasions due to their defined positions.

Non-flexing bundles optimize space utilization. Moreover, wiring harnesses manufactured by reputable wiring harness manufacturers in India play a crucial role in preventing short circuits and fires, as they are enclosed within insulated and secure materials.

This ensures a consistently secure and reliable electrical setup.

Elcom International provides essential wiring harness solutions tailored for diverse applications, encompassing medical equipment, industrial control panels, consumer appliances, solar applications, and more.

Elcom’s expertise in wiring harnesses is founded on a comprehensive approach to design, development, prototyping, and validation across the entire developmental phase.

The Wiring Harness offerings from Elcom encompass a range of cable sizes, spanning from 0.08 to 250 square mm.

We employ industry best practices, leveraging fully automated and semi-automated Cutting-unsheathing-stripping-crimping machines to ensure precision and efficiency in their manufacturing processes.

Wire harnesses is nothing but connecting two devices through wires or cables. It may a single wire or bundles of wires bound together. Due to its complex nature, let’s explore the elaborate details of wire harnesses, their application, and their manufacturing process.  

What are wire harnesses?  

Wire harnesses are typically a bundle of wires bound together by additional covering that helps guard against environmental conditions and other potentially harmful factors. The extra shell prevents the wire from wear and tear due to previously mentioned factors. These harnesses are essential because they are organized, so installing them into equipment becomes relatively more straightforward. Wire harnesses often get mistaken for cable harnesses or cable assemblies. Wire harnesses mainly provide easy organization of wires while installing equipment and only offer a certain degree of protection. In contrast, the cable assemblies bind multiple wires tightly to provide sturdy support against the environmental conditions in the picture.   

Wire harnesses provide numerous amounts of benefits, and they are:  

• Helps with wire management within the machinery setup   
• It gives a scope of optimization for specific situational needs  
• Increases the lifespan of wires and cables  
• Increases the safety of the equipment  
• They are available in a versatile range of lengths and sizes  

Few applications of Wire Harness  

Wire harnesses have a range of applications. Here is an elaborate list of several names of equipment and device that uses wire harness:  

• Locomotives: Wires harnesses are used in vehicles to relay information such as direction indication, electrical power, etc  
• In aerospace: Wire harnesses are used in flight simulators to transmit information while compliant with various performance standards and precise spacing requirements. This is done because aeronautical objects move with immense velocity, so to avoid any mishap with the wires, wires harnesses are used as they would provide some resistance to the atmospheric pressure and impact of air due to the velocity of the flying object.   
• The panel displays for flat screens: Flat screens use wire harnesses as there is already less volume in the body to fit all the critical components necessary for the screen to work.    
• Rugged computer- These computers are used in harsh environments like industries with heavy workloads and warzones. Hence wire harnesses are installed in the system as they are protected from dirt, dust, fungus, etc., due to the additional coverage that bounds them.   

Apart from the sectors mentioned above, Wire Harnesses are also used in machinery involved in industrial equipment, construction appliances, home appliances, military and defense systems, medical equipment, and many more. 

What is the manufacturing process of wire harnesses?  

The manufacturing process of wire harnesses is partly complex: 

The process always starts with its designing phase. Wires harnesses are used in industrial machinery, washing machine, etc. Hence its design also varies depending on its purpose and workload. Therefore, creating a customized wires harness is one of the challenging aspects of its manufacturing process. The engineers must consider the possible issues wire harnesses may face in particular machinery while designing them.    

Then a prototype is created to determine how the wire harness will work. The manufacturing process of wire harnesses is primarily manual. Manually assembled parts help resolve electric and space issues with certain complex products. The next step is called wire cutting. The wires are cut according to the machine requirement where the wire harness will be used. In the end, safety testing is run as it should for any electric component. In this last phase, utility and sustainability are checked rigorously.   

As one of the leading wire harness manufacturers in India, Elcom International offers a range of highly efficient wire harness solutions. ELCOM International, as one of the prominent harness manufacturers in India, specializes in creating electromechanical and electronic components with the mindset of producing world-class products. Backed by extensive research and advanced technology, Elcom International, a reliable wiring harness manufacturer, assures quality by complying with industry standards and manufacturing practices. Leveraging years of experience and expertise in the domain, Elcom International, one of the best wiring harness manufacturers in India, wins over competitors by incorporating top-notch practices and customer-centric solutions.  

Wire harness applications are utilized in nearly every conceivable household, industrial, or commercial device – tools, hardware, equipment, household, and machinery products – that relays or transmits electronic information or electrical power. The standard harness is definitely an essential, if not an indispensable, component in such devices. Wire harnesses are manufactured in various arrangements and sizes related to a device’s environmental and application requirements. The users can employ these devices anywhere from harsh outdoor climates with wide temperature extremes to temperature-controlled buildings, dwellings, or even marine environments at ocean level.

Components of wire harnesses consist of wires, terminals and connectors organized into consolidated, concise bundling systems. Designs vary enormously depending on the system requirements of these devices. Some applications are not more than a superficial bundle of loose wires grouped into an available protective jacket. Other applications may require a more complex assembly of dozens of individually over-molded wires and cables that feature breakouts that radiate off in multiple directions to termination points or other junctions.

Ultimately, wire harnesses supply efficient wiring solutions for electrical pieces of equipment and devices that will particularly impact those products’ overall performance, reliability, and stability. Their designated application, then, is crucial to the manufacturing of properly functioning products in every primary industrial sector. For a better comprehension, consider how these 5 general industries wholly or partially rely on wire harness applications in their products:

● Automotive Applications: To simply starting an automobile, motorcycle, truck, tractor, and so on relies on a variety of electrical devices and electronic controls to transmit electrical power and signals to turn the engine over and execute ignition. The transmission of those electronic signals is part of a massive wiring network that allows vehicles to function. That functionality is accomplished through wire harness applications that merge the engine management system, electronic controls, lighting, air conditioning, power steering, electric windows, power brakes, entertainment, and audio system, and so on into an efficiently operating and functioning vehicle. With many electronic units on board, it’s no wonder an average car has thousands of wires extending over a mile to connect operating systems and devices. Wire harnesses connect those devices and supply electricity and electronic signals throughout the vehicle.

● Manufacturing: Complex wiring, networks, cabling systems and drive robotic and automated production and assembly lines in today’s manufacturing facilities and plants. Wire harnessing applications connect signal and power conductors that control various systems along the same production line or within the same area. Wire harnesses ensure proper seal cabling, connectivity, and wires to ensure production is fully optimized.

● Medical Applications: In the healthcare domain, electronic medical equipment, instruments, and devices are subject to heavy use and varying degrees of low and high intensity. The wire harness applications fixed in these devices must be durable, biocompatible, and adaptable. Whether the device is a radiological or imaging equipment, defibrillator, pacemaker, or drill, it must function efficiently on demand without failure. Because of the myriad of applications, wire harnesses for the medical and healthcare sector come in all sizes and shapes. They differ significantly from other wire harness assemblies used in different industries. Wire harnesses for medical applications must be bio-sensitive and comply with FDA regulatory controls and guidelines.

● Communication Systems: Global connectivity demands an infrastructure that can send and receive data instantaneously worldwide. Communication systems depend on customized and personalized harnesses for a wide range of applications through an array of technologies. Wire harnesses are crucial components in the assembly of broadband networks, hubs, optical networks, routers, peripheral equipment, repeaters, modems, and much more. Wireless communication applications include RF, DSL routers, and satellite receivers.

● Military Applications: Wire harness capabilities for any military application must meet stringent DoD (Department of Defense) specifications. Cabling and wiring used in military equipment are designed for applications subject to extreme environments and conditions. Wiring harness manufacturers in India must manufacture military wire harnesses with components—wires, connectors, terminals—specified and approved for demanding military applications.

Elcom International- one of the leading electronic components manufacturers in India, has consistently served its esteemed customers with high-quality wiring harness products all across the globe. Being a wiring harness manufacturer, Elcom Internationals pursues an integrated development and manufacturing approach, which begins at the initial design phase of the product and lasts till the final validation phase of the product. These products provide reliable performance and long-term durability, coherent with our esteemed customer requirements and market demand.

Being the most reputable Wiring harness manufacturers in India, we ensure that all our wiring harness products are thoroughly tested before they are shipped to the customers. These wiring harness products are exclusively tested for continuity and polarization with the help of a pull test, as well as appropriate imaging and visual tests of various aspects. 

Wire harnesses are compactly bundled wires & circuits that function as the central nervous system of any Electrical System. Wire harness makes a critical component for a wide range of applications, including medical equipment, Industrial control panels, consumer appliances, and solar applications, etc. Generally, the Wire Harnessing offering includes cable sizes ranging between 0.08~185 sq mm and applies best practices using automated & semi-automated Cutting-Stripping-Crimping Machines.

As most of the infrastructure moves to the cloud, data centres built on a reliable IEC connector, such as Elcom, can utilize the wiring harness facility for faster processing and reduce the complexity while maximizing efficiency and reliability.

KEY SUCCESS FACTORS TO WIRE HARNESS BUSINESS
Wire harness finds its application from small, yet complex and flexible medical equipment to wide electronic equipment and appliances. The key success factor in this line of business lies in designing and following a world-class best practice.

Wire Harnessing capability is built upon an integrated approach towards design, development, prototyping, validation throughout the entire development period. Its characterised by both standardisation and at the same time having enough room for customisation and manufacturing flexibility in line with the specific requirement of the customer.

BEST PRACTICES CAN HELP IN COST CONTROL AND ACCURACY
Controlled flow of activities
• A variety of Wire Harness production should be carried out at one go with full control on the flow of activities.

Check for every parameter
• The thrust should be given on avoiding any kind of mixing of two different Wire Harness projects.
• Even for identical harnesses, with same wires, with same colours and same terminals.

Labelling
• Wires are identified from the moment it’s cut, stripped and terminated.
• The bundles are labelled, and made sure the areas where the wires are placed are clearly identified by part number, so there’s no possibility of mix-ups.

Bring Efficiency in the process
• Minimize work in process as much as possible, and try to make-to-order as best you can.
• In W/H drawings, case colour coding is mentioned in the drawings to match the colour of the wire, to avoid mistakes and save time.

Ensuring quality throughout
• Assembled harnesses is placed on pin boards, and each harness must pass functionality, and other customer-specific testing.
• On introducing new terminal, Crimp quality is tracked with Crimp-force monitoring.
• Crimping presses are configured so that if a bad crimp is detected, the machines either destroy the part or lock up, preventing the defective part from entering production.
• Each terminal crimper & anvil should be tracked by routinely taking cross-sections of crimped connections with Conductive Cable, after every 1,00,000 pieces.
• This test should be done to ensure that press dies have been set up correctly

ELCOM BRINGS TO YOU A HIGH QUALITY RELIABLE WIRE HARNESS SOLUTION
Elcom being a pioneer in the electronics components and Electromechanical solutions in India, have its own in-house design, manufacturing set-up of Wiring Harness, Power Cable Assemblies, IEC connector, Solar Connector & Solar wire Harness assemblies. Harness facility is UL approved under ZPFW2 category.

Elcom is further investing in developing an end-to-end Automated wire harness processing like cutting, stripping, crimping & testing unit. Elcom maintains safety standards norms by optimizing production process & avoid hazardous substances at every stage of manufacturing. The continuous focus on high quality products and processes enables ELCOM to provide the best possible connections to its esteemed customers. Our manufacturing system is well equipped to assure that our customers can expect the best-in-class customised solutions and hence high degree of performance and reliability.

Wire harnesses are compactly bundled wires & circuits that function as the central nervous system of any Electrical System. Wire harness makes a critical component for a wide range of applications, including medical equipment, Industrial control panels, consumer appliances, and solar applications, etc. Generally, the Wire Harnessing offering includes cable sizes ranging between 0.08~185 sq mm and applies best practices using automated & semi-automated Cutting-Stripping-Crimping Machines.

As most of the infrastructure moves to the cloud, data centres built on a reliable IEC connector, such as Elcom, can utilize the wiring harness facility for faster processing and reduce the complexity while maximizing efficiency and reliability.

KEY SUCCESS FACTORS TO WIRE HARNESS BUSINESS
Wire harness finds its application from small, yet complex and flexible medical equipment to wide electronic equipment and appliances. The key success factor in this line of business lies in designing and following a world-class best practice.

Wire Harnessing capability is built upon an integrated approach towards design, development, prototyping, validation throughout the entire development period. Its characterised by both standardisation and at the same time having enough room for customisation and manufacturing flexibility in line with the specific requirement of the customer.

BEST PRACTICES CAN HELP IN COST CONTROL AND ACCURACY
Controlled flow of activities
• A variety of Wire Harness production should be carried out at one go with full control on the flow of activities.

Check for every parameter
• The thrust should be given on avoiding any kind of mixing of two different Wire Harness projects.
• Even for identical harnesses, with same wires, with same colours and same terminals.

Labelling
• Wires are identified from the moment it’s cut, stripped and terminated.
• The bundles are labelled, and made sure the areas where the wires are placed are clearly identified by part number, so there’s no possibility of mix-ups.

Bring Efficiency in the process
• Minimize work in process as much as possible, and try to make-to-order as best you can.
• In W/H drawings, case colour coding is mentioned in the drawings to match the colour of the wire, to avoid mistakes and save time.

Ensuring quality throughout
• Assembled harnesses is placed on pin boards, and each harness must pass functionality, and other customer-specific testing.
• On introducing new terminal, Crimp quality is tracked with Crimp-force monitoring.
• Crimping presses are configured so that if a bad crimp is detected, the machines either destroy the part or lock up, preventing the defective part from entering production.
• Each terminal crimper & anvil should be tracked by routinely taking cross-sections of crimped connections with Conductive Cable, after every 1,00,000 pieces.
• This test should be done to ensure that press dies have been set up correctly

ELCOM BRINGS TO YOU A HIGH QUALITY RELIABLE WIRE HARNESS SOLUTION
Elcom being a pioneer in the electronics components and Electromechanical solutions in India, have its own in-house design, manufacturing set-up of Wiring Harness, Power Cable Assemblies, IEC connector, Solar Connector & Solar wire Harness assemblies. Harness facility is UL approved under ZPFW2 category.

Elcom is further investing in developing an end-to-end Automated wire harness processing like cutting, stripping, crimping & testing unit. Elcom maintains safety standards norms by optimizing production process & avoid hazardous substances at every stage of manufacturing. The continuous focus on high quality products and processes enables ELCOM to provide the best possible connections to its esteemed customers. Our manufacturing system is well equipped to assure that our customers can expect the best-in-class customised solutions and hence high degree of performance and reliability.