A wire harness is an organized collection of wires bound together. Electrical tapes, straps, and wire lacing are used to bind the wires together. It is an electrical system that is designed to supply electricity to any application. Therefore the design of cable wire harness is always according to the structure of the application. A Cable wire harness is used in a lot of gadgets and machines. The following industries involve heavy use of wire harnesses in their products
The automotive industry utilizes wire harnesses in car's electrical system
The medical industry involves the use of wire harnesses in medical gadgets
The defense industry makes use of wire harnesses in aircraft and defense technology
The electronics industry consists of heavy use of wire assembly in mobile phones and other electronic accessories.
A cable wire harness involves the use of multiple components like
Wires and Cables: These are the main components designed to distribute electrical signals within a device or application
Terminals: Metal components that are attached to the end of the wires that enable wires to be attached to connector housings
Connector housings: They are mainly mini plastic boxes that make a connection between wires secure and prevent it from loosening
Cable straps or lacing: These are utilized to bundle the wires together in a cable harness.
Neglect In Following the Assembly Diagram
An assembly diagram is a carefully designed circuit diagram that is drawn keeping in mind the specifications of the device or application. It is a blueprint of the entire cable wire harness. Applying hacks in connecting wires that do not match the pre-planned assembly diagram is a risky process that engineers should avoid as it can backfire and destroy the cable assembly, as a slight connection mistake can start a fire. In making and cable harness assembly going by the book is preferable, and strictly following the diagram is the way to success.
Incorrect Wire Selection
This mistake is usually made by inexperienced engineers as choosing a high-quality wire is the basic and foremost issue that should be kept in mind so that there are no faulty connections for the wire harness to function properly. Wires having ends that are stripped improperly and have been cut carelessly are low-quality wires that run dangers of weak connections.
Improper Crimping
Crimping means terminating the wires in a cable wire harness. Whether the wire harness is to be used in a large machine like a car or a small gadget, the crimping should be done with extreme accuracy, and all the wires should be terminated in a foolproof manner. Careless crimping would result in shortcircuiting that can lead to fire or explosion. To prevent such dire consequences, all wires should be terminated with utmost care and attention to detail.
Careless and Messy Soldering
This is another error that can undermine the functionality of a cable wire harness. Many manufacturers or engineers engage in neglect and in wire soldering. Incorrect soldering causes the heating up of wires which can lead to wire damage over the long term. Making use of the right soldering equipment can prevent this error.
Using Wrong and Inferior Hardware
Manufacturing industries are fast-paced with tight project deadlines. To save time and make execution quicker, careless engineers take shortcuts and overlook crucial wires that are vital for making the wiring harness successful, and this ultimately makes the whole wire harness useless and non-functional. In addition to this, many manufacturers use low-quality components like screws, clamps, and cable straps. This would result in loose bounding of wires which would mean that the cable harness would not last long over the years and would start to unravel.
Faulty Wire Tying
Once the wire harness assembly is completed, the final step is tying up wires by using plastic tie wraps. Too much tightening of tie wraps can damage the wires, and a loose wrapping means that wire bundles will open up and wire will get spread out, which may loosen connections. Manufacturers should pay attention to the wire-tying process to ensure that the right tension is applied in the tightening of wires.
FAQs
How do you find a short in a wiring harness?
Finding a short in a wiring harness can be a challenging task, but here are some steps you can follow to help locate and identify the short:
Visual Inspection
Closely inspect the cable wire harness for signs of damage.
Check for fuses blowing. If a short circuit is causing a fuse to blow again and again, then the location of the problem is near it.
Make use of a multimeter to check the resistance between positive and negative terminals.
Perform the wiggle test, which involves wiggling the wire while observing the multimeter.
Use a short finder tool to trace the short by running a current and detecting the magnetic field generated by the shorted wire.
What causes a wiring harness to fail?
Physical Damage: Any sort of cut, scratch, or crushing of wire
Excessive Thermal Stress: Melting of wire insulation due to engine temperature can lead to short circuiting
Corrosion: Moisture can seep into the wire and damage it.
Vibration and Shocks: Repeated shocks can loosen the connectors and cause electrical shortcircuiting.
Incorrect Repairs: Faulty and error-proof installation of wires after repair can lead to damage over time.
How do you know if a wire harness is bad?
A bad wire harness can cause various electrical issues in a system, and there are several signs that can indicate a problem with the harness. Here are some common symptoms that might indicate a bad wire harness:
1. Electrical Malfunctions: If you experience frequent electrical malfunctions, such as light flickering, intermittent power loss, or non-functioning electrical components, it could be due to a faulty wire harness.
2. Blown Fuses: If certain fuses keep blowing repeatedly, it may indicate a short circuit or overload in the wiring harness.
3. Burning Smell: A burning smell, especially near the wiring or electrical components, could be a sign of overheating due to a short circuit or electrical issue in the harness.
4. Visible Damage: Inspect the wiring harness for any visible signs of damage, such as frayed wires, melted insulation, or exposed metal. Damaged wires are a clear indication of a problem.
If you notice any of these signs, it's essential to inspect the wiring harness thoroughly or have it checked by a qualified mechanic or electrician. Diagnosing and repairing a faulty wire harness should be done with caution and expertise to avoid further damage and ensure the safety and reliability of the electrical system.
What is the easiest way to find a short in a wire?
The easiest way to find a short in a wire is by using a test light or a digital multimeter with a continuity (or beep) mode.
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