Wiring Harness

When it comes to manufacturing, most companies follow a wiring harness guide for the schematic of a newly designed unit. The journey of a wiring harness starts with a draft made by engineers and experts. Each design is tailored for the equipment or machine where it will be installed and therefore wire harnesses differ depending on the complexity of each application.

The main purpose of a wire harness is to efficiently distribute electrical signals throughout a device or machine. It also protects the entire electrical circuit from external elements that may be detrimental to the entire system. Wire harnesses in different industries utilize a wide variety of different materials which are considered more suitable for specific types of applications.

Wire harnesses are composed of numerous components. Some wire harnesses, such as those that are installed in automobiles, can even be comprised of thousands of parts. To further understand how wire harnesses work, it’s ideal to learn about the different components that make up the entire electrical network within each unit. Listed below are some of the most common parts found inside a wiring harness.

Conductors and Insulators- During the assembly process, the wires in a wiring harness guide should show the type of conductor and insulator that would be used. The conductor and insulator make up the entire wiring system that is distributed and laid throughout the harness. They act as the main pathways for the electricity that is needed by different parts to operate.

Fuses- Since a wiring harness operates through electrical signals, it’s important to always consider safety measures when it comes to designing a unit. Fuses are considered safety devices that can protect the entire electrical system from excessive current. It’s designed to fail and break the circuit when excessive current passes through. There are many types of fuses that may come in different shapes and sizes depending on the application. The five most common types of fuses are as follows:

  • Spade Fuse
  • Limiter Fuse
  • Lucas Fuse
  • Bosch Fuse
  • Glass Tube Fuse

Relays- When it comes to following a wiring harness guide, it’s always essential to carefully emulate where the relays are placed within the design. This can come with plenty of economical benefits and can also address complex wiring solutions that are needed for advanced technological features. To put it simply, relays are the on and off switches within an electrical system. Common types of relays are often electromechanical and require four main parts to operate. They are as follows:

  • Armature
  • Coil
  • Contacts
  • Main Frame

Terminals- The terminals in a wiring harness are responsible for establishing a connection between circuits. They are made to terminate a conductor that must be connected to a stud, post, or chassis. Much like the other components, terminals may come in different shapes and sizes depending on the device or application.

Fasteners and Binders- When following a wiring harness guide, manufacturers must take into account the durability of each component. This would only be made possible by using locks, ties, and grommets that can hold each part of the entire electrical system. For other components, skilled workers carefully solder them in place to avoid any risk of post-production issues.