Often a wiring harness is not a priority with an in-house design team. They may create a general wiring bundle or a group of wires, but there is little consideration in creating a compact, secure and carefully designed harness.
Working with a company that creates custom wiring harness assemblies is a great option. These contract manufacturing companies typically have specialized engineers and design teams that work with the entire electronic component and also create a custom harness. It is also possible for an OEM to simply outsource the design of the custom cable or wiring harness.
The Basics
Whether the contract manufacturing company is making the electronic components and the custom wiring harness or just the harness, the first step is to understand the wiring system as well as the specifics for the application.
For instance, there may be equipment where a very compact space is all that is available, so the wiring harness has to take into consideration the size of the bundle as well as the best locations to position the wires within the system.
Simple wiring harnesses may have two to four or five wires, and they may have a range of different connectors in use. The entire wiring harness assembly may be very simple and drop into the system. It is also possible for a custom wiring harness to be tens or hundreds of wires, each with unique connectors and very specific positioning of all components. A good example of a complex type of system like this would be found in military and defense equipment, in complex automated systems or in aerospace equipment.
The Benefits
In designing a custom harness for wires or cables, the goal is to simplify the installation process into the system. This limits the risk of human error in running the wires through the system and also creates a wiring bundle that is protected and secured, enhancing life cycle and reducing the risk of system failure.
