Wire Harness Assembly

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Tricks Up Our Sleeving

Wire Harness Assemblies are integrated arrangements of cables within insulated sleeving or jacketing. These assemblies include multiple terminations in complex arrangements for flexible applications. PGF terminates, cuts, crimps, twists, and pulls their way to the top of the pack in terms of harness assembly projects.

Complex harnesses require detailed instruction and preparation. The PGF team implements digital work instructions with step-by-step procedures to construct the best plan for harnessing your power!

Assembly Methods

These assembly methods for wire harnesses offer different techniques to achieve secure connections, proper insulation, and protection. The choice of method depends on factors such as the application requirements, wire type, connector type, and desired level of durability and aesthetics.

Crimping

  • Stripping and preparation: Strip the insulation from the wire ends.
  • Terminal selection: Choose the appropriate crimp terminals based on wire gauge and connector type.
  • Crimping: Use a crimping tool to securely attach the terminals to the wires.

Soldering

  • Stripping and tinning: Strip the insulation and tin the wire ends by applying solder.
  • Component soldering: Solder the tinned wires to the respective connectors or terminals.
  • Heat shrink tubing: Slide heat shrink tubing over the soldered connections and apply heat for insulation and protection.

Wire Harness Assembly Layers

The wire conductors form the core layer of a wire harness assembly. These are individual wires that carry electrical signals or power between components.

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The insulation layer surrounds each wire conductor, providing electrical insulation and preventing the wires from coming into contact with each other or external elements. It helps maintain signal integrity and prevents short circuits.

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In applications where electromagnetic interference (EMI) protection is required, a shielding layer is added. It consists of conductive material, such as metal foil or braided wire, which helps minimize the impact of external electromagnetic noise on the signals transmitted through the wires.

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The outer jacket is the final layer of a wire harness assembly. It encases the wires and provides mechanical protection against abrasion, moisture, chemicals, and other environmental factors. The outer jacket is typically made of materials like PVC, TPE, or Polyurethane.

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Wire Harness Assembly Process

Most wire harnesses are designed with a specific application or device in mind for optimal functionality and safety. The most important factors to consider during the design process are space requirements, installation preferences, and power demands of the equipment or device in which the harness will be used. Other factors to consider include temperature, chemical exposure, humidity, flexibility, and color preferences. In general, the length of time required to manufacture the wire harness assembly will depend on the design’s complexity.

Given the complexity of wire harness assembly manufacturing, working with a provider with the relevant design and manufacturing experience is essential to meet your specific requirements. Creating a wire harness assembly typically involves the following key steps.

Wire Preparation

Cut the wires to the required lengths based on the design specifications. Remove the insulation from the ends of the wires using wire strippers to expose the conductor.

Crimping or Soldering

Attach terminals or connectors to the stripped wire ends using a crimping tool. Crimping creates a secure mechanical and electrical connection between the wire and the terminal. Apply solder to the stripped wire ends and the terminal or connector, and heat the joint with a soldering iron to create a permanent connection.

Terminal Assembly

Insert the crimped terminals into their corresponding housing or connector. Secure the terminals in place by locking or latching them within the connector housing.

Harness Routing and Bundling

Arrange the wires in the desired configuration, following the routing paths specified in the design. Use cable ties, tape, or sleeving to bundle and organize the wires together, ensuring a neat and organized appearance.

Testing and Inspection

Use specialized equipment to test the continuity and integrity of the wire connections, verifying that the assembled harness functions properly. Inspect the wire harness assembly for any physical defects, such as loose connections, exposed wires, or incorrect routing.

Protective Covering

Apply a braided sleeve or heat-shrink tubing over the wire harness to provide additional protection against abrasion, mechanical stress, and environmental factors. Apply heat to the heat-shrink tubing, causing it to shrink and conform tightly around the wires, providing insulation and strain relief.

Labeling and Marking

Attach labels or markers to identify individual wires, terminals, or specific functions, aiding in installation, maintenance, and troubleshooting.

Final Quality Check and Packaging

Conduct a final visual and functional inspection to ensure that the wire harness assembly meets all the required specifications and quality standards. Package the assembled wire harnesses appropriately for storage, transportation, or direct installation in the intended devices or systems.

Industries Served

Wire harness assemblies find extensive applications across various industries, including automotive, aerospace, industrial machinery, and electronics. They are crucial components in vehicles, aircraft, manufacturing equipment, and electronic devices, providing reliable and organized electrical connections for power distribution, signal transmission, and control systems. Wire harness assemblies play a pivotal role in ensuring efficient and safe operation, making them indispensable in industries that rely on complex electrical systems and require high-quality, durable wiring solutions.

automotive ev and charger

Dennis Moore | Bosch

Many times we fail to let our supplier and customer service representative know we appreciate the job you and your company have done for us in supplying our wiring assemblies. PGF is a very reliable supplier in terms of on-time delivery with a quality product. I’m sure your attention to detail and documentation requirements help you achieve both.

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