Wire harnesses are nothing but connecting two devices through wires or cables. It may be 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.