Wire Harness Product Introduction
A Wire Harness is an electrical transmission component assembled by multiple wires or cables by a specific topology to achieve efficient transmission of power, signal, and data through a standardized bundling process. As the core connectors of modern electrical systems, wire harnesses have become an indispensable basic component for modern intelligent manufacturing by optimizing space layout and enhancing transmission reliability, which significantly improves the assembly efficiency and operational stability of various electrical systems.
Wiring Harness Components
1. Conductor system
Conductor material: high-purity copper (conductivity ≥ 99.9%) or aluminum alloy
Cross-sectional area range: 0.85-20mm² (graded according to IEC 60228 standard)
Insulation: PVC/XLPE/silicone rubber, etc. (temperature resistance range -40℃~200℃)
2. Interconnection components
Terminals: made of phosphor bronze/brass (contact resistance <5mΩ)
Connector: comply with USCAR-2/ISO 8092 and other industry standards
Waterproof grade: IP67/IP69K (automotive grade requirement)
3. Mechanical fixing program
Constraints: Nylon cable ties (UL94 V-0 flame retardant)
Positioning clips: PP/PA66 engineering plastics
Protective sleeve: below/weave mesh (abrasion resistance class ≥ 50,000 times)
All components are required to pass environmental reliability tests such as vibration (20- 2000Hz) and salt spray (96h) to ensure long-term stability under complex working conditions. Typical automotive wiring harnesses contain 300-5000 connections and need to meet the requirements of a 15-year/250,000km service life.
Classification of wire harness
1. Divided by function type
Power transmission harnesses
Carrying high current (up to 600A), using thick insulation (1.5-3mm), typical applications: new energy vehicle power system.
Signal Transmission Harnesses
Twisted pair/shielded wire structure, impedance control (50Ω/75Ω), typical application: vehicle CAN bus.
Data Communication Harness
High-frequency coaxial cable (up to 10 Gbps), compliant with USB3.0/HDMI2.1 and other protocols, typical application: intelligent cockpit system.
2. Classified by protection characteristics
Waterproof type (IP67/IP69K)
Sealed connector, wrapped with waterproof tape, application scenario: chassis wiring harnesses
High temperature resistant type (-40℃~200℃)
Silicone rubber insulation, silver-plated terminals, application scenario: engine compartment.
Flame retardant type (UL94 V-0)
Ceramicized silicone material, metal protective sleeve. Application Scenario: Battery pack wiring harness.
The core function and role of the wiring harness system
1. Systematic circuit integration
Adopting topology optimization design, 200-5000 independent wires are integrated into a modular wiring harness system, realizing structured interconnection of 300+ electrical components such as ECU, sensors, actuators, etc.
Typical application: automotive CAN bus network integration of 12 subsystems communication
2. Multi-modal transmission hub
Supporting a wide voltage range of 12V-800V (up to 300A for new energy vehicle high-voltage harnesses), the transmission rate covers 10Kbps-10Gbps (e.g., in-vehicle Ethernet), which meets the demand for real-time data exchange under the AutoSAR architecture.
3. Reliability Enhancement System
Triple protection design: physical protection (wear-resistant braid + metal sheath), chemical protection (oil/corrosion-resistant coating), and environmental protection (-40℃~150℃ wide temperature range adaptation).
Failure rate reduced to <50PPM (Six Sigma standard)
4. Engineering efficiency optimization
Pre-assembly mode reduces loading man-hours by 40%, and modularized design shortens maintenance time by 60
Typical example: Volkswagen MQB platform wiring harness common rate of 75%
5. Cross-field application expansion
New Energy Vehicle: High-voltage wiring harnesses meet ISO 6469 insulation requirements.
Industry 4.0: Support PROFINET industrial bus protocol.
Aerospace: meets AS50881 cable standard.
Wiring harnesses are mainly used on PCBs to connect multiple PCB assemblies or circuit boards to each other, to ensure that cables are connected without error, and to keep all wires and cables organized and managed. Wiring harnesses enable the functioning of electronic devices by connecting multiple PCB assemblies together to form a complete circuit system.
Types of wire harnesses and their applications on PCBs
Point-to-point cable harnesses, which are the simplest type of wiring harnesses, use point-to-point cable bundles and pack them into individual harness assemblies. This type of harness is usually used to connect a pair of PCBs to ensure that the cables are connected without error.
Bifurcated cable, the cable coming out of the connector can be bifurcated and is used to connect one PCB to at least two other PCBs.This harness type is useful in applications where multiple connection points are required.
Flexible Printed Circuit (FPC) Cables, Flexible Ribbon Cables can also be used as a harness, allowing a mix of edge connectors, surface mount connectors and even through-hole connectors to interface with a set of PCBs. Flexible cables are very flat and are suitable for designs where space is limited.
Advantages of wire harness
1. Improve system reliability
Wiring harnesses ensure the stability and reliability of electrical connections through standardized design and manufacturing processes. Each wire in the harness is precisely measured and tested to ensure that it meets specific electrical performance requirements. This standardized manufacturing process reduces the likelihood of human error and assembly mistakes, thus increasing the reliability of the entire system.
2. Simplified installation and maintenance
The modular design of the wiring harness makes the installation and maintenance process easier. Wiring harnesses are usually provided in the form of pre-fabricated, the installation of which only needs to be connected to the appropriate interface, greatly reducing the installation time and complexity. In addition, the marking and color coding of the wiring harness makes troubleshooting and repair easier, allowing technicians to quickly identify and replace problematic parts without the need for complex disassembly and rewiring of the entire system.
3. Improve production efficiency
In industrial production, the use of electronic wire harnesses can significantly improve productivity. As the harness is pre-designed and manufactured, workers on the production line only need to follow a standardized process for assembly, reducing the complexity of the electrical connection operation. This not only reduces production time, but also lowers production costs. In addition, the standardized design of the wiring harness also makes mass production possible, further improving production efficiency and economic benefits.
4. Space and weight saving
Electronic wire harnesses reduce wire clutter by bundling multiple wires together in an orderly fashion, thus saving space inside the device. This is especially important for electronic devices where space is limited, such as automobiles, aerospace equipment, and portable electronics. In addition, the design of wire harnesses can also optimize the length and layout of wires, reducing unnecessary wire lengths and thus reducing the overall weight of the equipment.
5. Enhanced safety
Electrical safety requirements are usually taken into account in the design and manufacture of wire harnesses. The wires in the harness are usually wrapped with insulating materials to prevent safety hazards such as short circuits and leakage. In addition, the fixing and protection measures of the wire harness, such as the use of protective sleeves and fixing clips, can prevent the wires from being affected by mechanical damage or environmental factors during the operation of the equipment, thus enhancing the safety of the equipment.
6. Adaptation to complex environments
The design of electronic wire harnesses can be adapted to a variety of complex operating environments. For example, in the automotive industry, the harness needs to withstand high temperatures, vibration and humidity and other harsh conditions; in the aerospace field, the harness needs to have the ability to resist radiation and electromagnetic interference. Through the use of special materials and technologies, wire harnesses can work stably in these complex environments.
Application areas of wire harnesses
1.Motor
Wiring harnesses are widely used in a variety of motors, including motors for daily necessities, industrial products, and automobile motors.
2.Office equipment
Wiring harnesses are used in office equipment such as printers, copiers, and scanners.
3.Industrial Equipment
Wiring harnesses have important applications in the industrial field, such as inkjet barcode printers, laser printers, industrial power supplies, power protectors, testing equipment and so on.
4.Financial equipment
Wiring harnesses are also widely used in financial equipment, such as ATM, cash registers, terminals, and so on.
5.Medical equipment
Wiring harnesses are used in medical equipment such as monitors, anesthesia machines, digital ultrasound machines, blood/biochemistry analyzers, radiological imaging equipment, etc.
6.IT products
Wiring harnesses are also used in IT products such as laptop computers, multimedia stereos, monitors, cell phones, power supplies, and security equipment.
7.Automotive
Wiring harnesses are especially important in automobiles, The body harness connects the entire body, and the shape is roughly H-shaped, widely used in a variety of electronic devices and systems in the car.
In addition, wiring harnesses are also widely used in other fields, such as household appliances, computers and communication equipment, various electronic instruments and meters.