Wire Harness Assembly

Wire Harness Assembly Design & Production

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 Processing

Once the customer and manufacturer establish the geometric and electrical requirements, a detailed schematic ensures that the assembler follows all design and electrical guidelines throughout the production process. This process involves creating an assembly board, which provides a full-size diagram of the wire harness and the proper location of its wires and components. The wire harness assembly board also provides a workbench for assembling and clamping the wires together.

Wire Marking & Cutting

Suppliers provide the wires required for the assembly in a master reel. Each wire is carefully measured, marked, and cut to the appropriate length. If needed, individual wires within the assembly can be identified using labels or barcodes.

Wire Stripping & Termination

The ends of the cut wires are then stripped and fitted with the appropriate terminals. Wire terminals are responsible for establishing the required connection for the application. Typically, manufacturers add terminals by crimping them onto one or both exposed wire ends using an automated or manual crimper.

Wire Layout

The wires and subassemblies are arranged and installed on the assembly board and routed through any necessary connector housings or conduits. Team members then bundle all components and wires together using sleeves, wraps, ties, tapes, or combinations.

Post-Production Testing

Once the wire harness assembly is complete, post-production testers verify the final product’s electrical functionality and safety. In addition to visual inspection, this process utilizes digital test boards to look for defects. Quality inspectors evaluate the unit’s durability under the relevant environmental conditions. The assembler then performs any final operations to prepare the harness for packaging and shipment.

Wire Harness Assembly Applications

With their cost- and space-saving benefits, wire harness assembly processes have become a valuable part of the consumer, commercial, and industrial electrical devices and systems. Examples include:

• Electronics: In electronic devices, wire harness assemblies are responsible for supplying power and transmitting data required for operation. Their uses include personal computers, laptops, diagnostic medical devices, machinery, and more.
• Automotive: Wire harnesses provide vehicle manufacturers with an affordable and efficient way to keep individual wires, cables, and subassemblies conveniently grouped in a single unit. In practice, teams embed these units in the vehicle’s engine, chassis, and body to transmit signals and deliver power.
• Construction machinery and industrial equipment: Durable wire harness assemblies are critical for operating heavy construction and industrial equipment operation. They ensure reliable transmission of electrical signals while keeping wires protected from abrasion, impact, and vibration.
• Household appliances: Wire harness assemblies enhance the safety and reliability of household devices such as washing machines, dryers, dishwashers, and refrigerators.