Wire harnesses are specially designed bundling systems that are used to keep numerous wires and cables organized into a bunch. While earlier, the entire process of manufacturing a wire harness was manual, today, there are a number of machines used to make the process automatic. However, only certain processes can be made automatic, with other processes requiring manual assistance. Thus, no wire harness manufacturing process can be completely automatic; it can only be a semi-automatic procedure.
Wire harnesses involve dozens of individually overmoulded wires branching off into different directions and junction points. Rather than manually routing and connecting all such individual strands, wires are cut to length, bundled, and clamped to terminal and connector housings using automatic machines, thus reducing labour time and human error, and also increasing the speed of manufacturing. However, the complex design of wire harnesses may pose several issues, especially if the harnesses are made of low quality materials, or by unskilled men at work. This is why when you want connectors and wire harnesses for your products, you must choose to have your products manufactured and supplied by only experienced and reliable wire harness manufacturers from India, one like Miracle Electronics.
There must be a complete design laid out in front before the manufacturing of wire harnesses begins. Without a working knowledge of how every connector component contributes to performance, developers may end up with a poorly designed product.
Issues with contacts
One of the most common points of failure in wire harnesses are the contacts, which are tiny metal pins and parts that touch to form an electrical connection. If the connector is not properly connected, contacts may get grimy or corroded with time, thus affecting the flow of electricity. Moreover, the contacts have a limited life span; thus if they are not designed for the number of mating cycles required, they may lose their resilience over time, causing the connector to prematurely fail.
Crimping issues
Wires are attached to connectors or terminals with the help of a crimping method, which involves the use of a specialized tool that creates a gas-tight fusion between the two parts. But, the technique used should be perfect to make tight crimps, because loose crimps will allow moisture to penetrate the joint and cause corrosion, which may lead to short circuits, open circuits, or electric failure.
Overmolding material selection
The material used for overmoulding to protect the connector is decided based on environmental conditions and the mechanical demands of the application; and it is this material that significantly influences the life span of a wire harness system.
Strain relief
Strain relief is a design feature that allows for force transfer in any direction to enhance the mechanical strength of the connection. If enough strain relief in not possessed in a connector, the wiring will pull apart from adjoining terminals, leading to failure.
Given all these complexities, you don’t want to take any risk to raise any kinds of issues. This is why you need high reliability wire harness manufacturers from India to manufacture your products.
