FAQ
What are the key considerations for wire harness routing?
Harnesses should be routed to avoid sharp edges, hot surfaces, and moving parts. Signal and power lines should be separated to prevent interference, and the path must allow for strain relief and easy maintenance
What is the difference between a wire harness and a cable assembly?
A wire harness is a bundled set of wires and cables, often with multiple branches, organized with sleeves or tape for internal organization. A cable assembly typically groups conductors into a single, robust external jacket for protection in harsh environments
How do you determine the correct wire gauge for a harness?
Wire gauge is selected based on the current-carrying capacity, voltage drop over length, and mechanical strength needed. Using an undersized gauge can cause overheating, while an oversized one adds unnecessary cost, weight, and rigidity.
What is the purpose of a wire harness schematic?
A schematic is a logical diagram showing the electrical connections between all points. It is the master blueprint that defines the circuit's functionality, including wire colors, gauges, and pin-outs for connectors.
What are the first steps in designing a custom wire harness?
The process begins with understanding the electrical and mechanical requirements, including current load, voltage, signal type, environmental conditions, and connector interfaces. Using these parameters, a schematic and a 2D formboard drawing or 3D model are created for manufacturing