Wire harnesses are one of the most important components of electrical and electronic systems. They are highly useful to combine wires into neatly assembled bundles to keep the wires secured and operators safe from hazards. If you are planning to purchase wire harnesses, especially customized ones, it is advised that you identify all your requirements beforehand so that you can build a wire harness that complies to all your needs. After all, identifying all your wire harness requirements before the design process can help you strengthen product development efforts. Miracle Electronics is the best wire harness manufacturer in India that you can rely upon to build the finest customized wire harnesses for you that cater to your requirements completely, avoiding over-designing that can add to your expenses, and under-designing that fail to meet your expectations. Mentioned below are some of the basic factors one must consider while designing a wire harness design.
Electrical requirements
Because wire harnesses are related to electrical and electronic systems, it is highly essential that they meet specific electrical requirements. These may include operating current, operating voltage, connector-related resistance, number of contacts, grounding, signal speed, and separation of power and signals.
Operating environment
The operating environment that the wire harnesses need to be used in is of utmost importance to avoid hazards or damage of the harnesses or equipment. If wire harnesses are to be used in harsh climates and extreme temperatures, it must be clearly mentioned. Other operating environments include chemicals, pressure, and humidity.
Quality
Quality of the wire harnesses to be used must be standardized and approved by the norms of DGAQA and MSQAA. Also, the production processes must be certified for quality to an ISO 9001 standard to prove that a quality management system is followed.
Safety and regulatory requirements
Safety is one of the prime concerns when it comes to handling electrical and electronic systems and equipment. This is why wire harnesses need to comply with several safety and regulatory requirements like Restriction of Hazardous Substances (RoHS), Registration Evaluation Authorization and Restriction of Chemicals (REACH) compliance, UL, CE, etc.
Cable type
There are two basic types of cables you can choose from – flat and round. Flat cables are used for mass termination, while round cables are used for long cable runs, or when flexibility and compactness are required. But, both these types of cables come in multi-conductor or twisted pair configurations, and are available with or without shielding, as required. So, make sure to choose your cable types wisely.
Coupling mechanism
There are various coupling mechanisms available for implementation in wire harnesses, like threaded connectors, push-together connectors, and Bayonet-style connectors. It is important to understand such connections, and also to analyze what kind of coupling mechanism will suit your requirements.
Miracle Electronics is a leading wire harness manufacturer in India who has all the experience and capabilities to customize a wide range of wire harnesses of all types, with all quality procedures kept in check and certified for quality to ISO 9001, AS9100C; and the products approved by DGAQA and MSQAA for platform specific applications. Additionally, all the wire harnesses are tested for dimension, weight, continuity, high pot, pull tests, and compliance to environmental requirements.