100mm Wire Harness Assembly PVC black ROHS Waterproof Automobile Harness Motorcycle Connection Wire Special Equipment Wireless

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A wire harness can be simple, two wires with basic terminals on the end, or a complex web of many conductors with a variety of connectors and terminations. In addition, wire harnesses often need special shapes, sheathing, mechanical fastening and over molded connectors, grommets or strain reliefs. Our cable can assist in the custom wire harness design or quote your existing wire and cable harness design. We’re ready to help solve your cable assembly and wire harness needs.

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Once a design is established, the process of building a wire harness starts with the development of a schematic that is used to create the manufacturing paperwork and the assembly board for the harness. The assembly board, or pin board, is a full size diagram of the harness and shows all of the components and their location and also serves as the workbench for the harness. The wires needed for the harness are supplied on a master reel and are cut to the desired length and identified with printing or labeling if necessary. Once cut to the proper length, the wires are stripped to expose the uninsulated conductor and then fitted with any required terminals or connector housings. These wires and components then are put on the pin board and are bound together by any necessary straps, cable ties, cable lacing, sleeves, tapes, weaves of extruded string, or any combination of these.

How Metal Becomes Wire

First, the majority of electrical wire is made from aluminum or copper. After refining the ore, metal is pulled into thick coils called rod. Rod is processed in large spools and then fed into a series of dies and rollers which stretch it out into its final thickness, or “gauge”. To be useful and to be safe, bare wire is covered in a continuous insulating sheath using various kinds of plastic that must withstand temperature extremes, solvents, water and UV exposure. This is performed with a plastic extrusion process not much different than that used to make plastic bottles.

Only a few kinds of plastic are best suited as insulation since they must be durable, flexible, accepting of different colored dies, and not too expensive. Common material includes polyethelene (PE), polyurethane (PU), rubber and polyvinyl chloride (PVC). Higher grades of material for better durability and mechanical strength may include nylon, silicone, FEP, and PTFE (Teflon).

How Wires Become Cables

Usually a single solid metal strand is considered a wire, while multiple strands or bundles of wire are called a cable. In both cases, they are conductors for electrical signals. They come in many types and sizes for power transmission and telecommunication. Telecom cables are often shielded, using an additional outer mesh of conductor separated from the inner core by an insulating layer. This secondary mesh is meant to prevent incidental electromagnetic radiation in the environment (radio, TV, mobile phone signals) from interfering with the transmission.

Connectors And Terminals

By themselves, wires and cables can do nothing. They must be connected to something to perform their function, and that’s where connectors come in. But what exactly is a connector? Well, a connector actually needs to perform a couple of functions that can be highly specialized.

Connectors use a metal terminal that is crimped or soldered to a corresponding conductor, and all of this is placed inside the plastic shell. Connectors are tasked with making mechanical joints between male and female terminals, not only holding the whole unit firmly in place but also protecting it from the outside environment. Usually the connector can be separated later for maintenance or replacement, making it an invaluable interface between the human user and the electrical device. And there are thousands of types of connectors in every conceivable size and shape, for every kind of device and purpose.