Any kind of cable harnesses you wish to install into any of your applications, you need to be sure that they meet industry standards and application requirements. And for this, you need to purchase your products from a trusted dealer like Miracle Electronics, one of the largest suppliers and leading cable harness manufacturers in India. Cable harnesses can be entitled as perfect if they are checked and tested for various confirmations, and comply with every requirement and standard. There are various processes that ensure proper wiring and electrical aspects, which ultimately result in 100% positive results while performing the tests. Below mentioned are some of the most important processes involved in the construction of cable harnesses.
Soldering
This is a kind of manual termination wherein two wires are joined together for conducting electric currents. This can be done by hand for short manufacturing runs. However, for larger manufacturing runs, automated wire soldering machines are used. These soldering machines ensure that customer demands from both quantity and lead time perspectives are met.
Semi-automated termination
Semi-automated termination should be performed and utilized to the highest possible extent in order to keep costs under control; that is, offering highest quality terminators at the lowest possible costs.
Plastic welding
Ultrasonic plastic welding machines are used to join two pieces of plastic together to complete the plastic welding process. Cable harnesses and connectors that are too small, complex, or delicate are plastic welded in this manner as other welding techniques may seem impossible in these cases.
Over molding
Over moulding is the process of moulding industrial plastic over connectors, splices, and toggle switches with the help of plastic injection molding machines. This process protects the elements against corrosion, heat, or any other powerful impact that they may encounter in any kind of application. Moulds may also include product names, customer names, logos, or any other form of artwork required by the customer.
Insertion loss analysis
Performed on high speed cable harnesses, the insertion loss analysis test checks the frequencies of all the wires to safeguard them against spikes, suck-outs, and electrical losses.
Electrical testing
Completely constructed cable harnesses are tested for faults like shorts or open through electrical testing (also known as signal integrity testing). This kind of testing also checks for ensuring appropriate pin-outs and shield integrity.
Physical analysis
Reliability in all kinds of electrical products is essential. This is why cable harnesses should be physically analyzed to ensure that they can withstand all kinds of rigorous and harsh environments, as expected by the customers.
Environmental analysis
Along with physical analysis, cable harnesses must also undergo environmental analysis to guarantee that they can undergo everyday abuse which they may encounter and be exposed to, while maintaining high performance.
All the processes mentioned above are highly crucial in cable harness construction and testing to ensure that the cables and harnesses are manufactured to meet the expectations of the customers, demands of the market, and requirements of the applications they are used in.
