Cable harness

<h2 id="design">Design</h2>
The design of a wire harness usually requires the effort of two main engineering disciplines that focus on different functioning requirements, mechanical engineering and electrical engineering. Mechanical engineering focuses on the physical parameters of a wire harness and its interaction with the environment it will endure during its lifetime. This considers the operating conditions the wire harness is meant to operate under, i.e. temperature, mechanical stress, environmental and chemical wear. This component considers the protective materials wire harnesses have like corrugated tubes, braided or silica sleeves.
Electrical engineering focuses on developing the logical, electrical and topological architecture of the wire harnesses. During the design of electrical wires, one must consider the operating ratings of wires for communication protocols and design standards developed by entities like <a href="/facts/American_Society_of_Mechanical_Engineers/gpM3UR6G">ASME</a>, <a href="/facts/International_Organization_for_Standardization/IacYR7Yg">ISO</a> or <a href="/facts/Japanese_Automotive_Standards_Organization/VfCKFGjC">JASO</a>.<a class="footnote-ref" id="fnref:4" href="#fn:4">4</a>

<h2 id="productions">Productions</h2>
Cable harnesses are usually designed according to geometric and electrical requirements. A diagram is then provided (either on paper or on a monitor) for the assembly preparation and assembly.
The wires are first cut to the desired length, usually using a special wire-cutting machine. The wires may also be printed on by a special machine during the cutting process or on a separate machine.<a class="footnote-ref" id="fnref:5" href="#fn:5">5</a> After this, the ends of the wires are stripped to expose the metal (or core) of the wires, which are fitted with any required <a href="/facts/Terminal_(electronics)/CwbKGSuB">terminals</a> or <a href="/facts/Electrical_connector/rJh0cHs6">connector housings</a>. The cables are assembled and clamped together on a special <a href="/facts/Workbench/MFHVUYL8">workbench</a>, or onto a pin board (assembly board), according to the design specification, to form the cable harness. After fitting any protective sleeves, conduit, or extruded yarn, the harness is either fitted directly in the vehicle or shipped.
In spite of increasing <a href="/facts/Automation/3YlF2K5q">automation</a>, hand manufacture continues to be the primary method of cable harness production in general, due to the many different processes involved, such as:

<ul><li>Routing wires through sleeves,</li>
<li>Taping with fabric tape, in particular on branch outs from wire strands,</li>
<li><a href="/facts/Crimp_(joining)/kA8DrJPv">Crimping</a> terminals onto wires, particularly for so-called multiple crimps (more than one wire into one terminal),</li>
<li>Inserting one sleeve into another,</li>
<li>Fastening strands with tape, clamps or <a href="/facts/Cable_tie/uzu02RCz">cable ties</a>.</li></ul>
It is difficult to automate these processes, with major suppliers still using manual means of production, only automating portions of the process. Manual production remains more cost effective than automation, especially with small batch sizes.
Pre-production can be automated in part. This affects:

<ul><li>Cutting individual wires (cutting machine),</li>
<li>Wire stripping (automated wire stripping machines),</li>
<li>Crimping terminals onto one or both sides of the wire,</li>
<li>Partial plugging of wires prefitted with terminals into connector housings (module),</li>
<li><a href="/facts/Soldering/fod6dLHD">Soldering</a> of wire ends (solder machine),</li>
<li><a href="/facts/Twisted_pair/L426Jk2C">Twisting</a> wires.</li></ul>
A wire harness<a class="footnote-ref" id="fnref:6" href="#fn:6">6</a> must also be manufactured with a terminal, defined as "a device designed to terminate a conductor that is to be affixed to a post, stud, chassis, another tongue, etc., to establish an electrical connection."<a class="footnote-ref" id="fnref:7" href="#fn:7">7</a> Some types of terminals include ring, tongue, spade, flag, hook, blade, quick-connect, offset and flagged.<a class="footnote-ref" id="fnref:8" href="#fn:8">8</a>

Once a cable harness has been produced, it is often subject to various tests to ensure its quality and functionality. A test board can be used to measure the harness' electrical capabilities. This is achieved through the input of data about a circuit which one or more cable harnesses will be part of being programmed into the test board. The harness is then measured for its ability to function in the simulated circuit.<a class="footnote-ref" id="fnref:9" href="#fn:9">9</a> 
Another popular test method for a cable harness is a 'pull test', in which the harness is attached to a machine that pulls the harness at a constant rate. This test then measures the cable harness' strength and electrical conductivity when pulled against a minimum standard to ensure that cable harnesses are consistently effective and safe.<a class="footnote-ref" id="fnref:10" href="#fn:10">10</a>

<h2 id="in-sound-engineering">In sound engineering</h2>
The cable harnesses used in <a href="/facts/Sound_reinforcement_system/s480anBh">sound reinforcement</a> and <a href="/facts/Recording_studio/zlGNwv0g">recording studios</a> are called <a href="/facts/Audio_multicore_cable/yvWo1XCX">multicores</a>, also known as snakes or looms. They carry <a href="/facts/Audio_signal_processing/HXvBpspA">audio signals</a> between a <a href="/facts/Mixing_console/APIwbRBg">mixing console</a> and <a href="/facts/Stage_box/garh8zVR">stage box</a>. Modern <a href="/facts/Digital_mixing_console/BF8RAxFJ">digital mixing consoles</a> typically use a single <a href="/facts/Twisted_pair/L426Jk2C">twisted pair</a> cable rather than a traditional analog multicore.

<h2 id="industry-quality-standard">Industry quality standard</h2>
Although customer specifications take the highest priority when creating cable harnesses of a certain quality, in North America if no such specifications are found the quality standards of a cable harness are standardized by the <a href="/facts/IPC_(electronics)/Db8nM9TY">IPC</a>'s publication IPC/WHMA-A-620E for minimal requirements for cable harnesses.<a class="footnote-ref" id="fnref:11" href="#fn:11">11</a><a class="footnote-ref" id="fnref:12" href="#fn:12">12</a> This publication is reviewed frequently to ensure that the standards published remain of an acceptable standard in light of potential changes to the industry or technology that may occur. The IPC/WHMA-A-620E publication has standards for a wide range of elements within a cable harness, including but not limited to <a href="/facts/Electrostatic_discharge/I55BBYfS">electrostatic discharge protection</a>, <a href="/facts/Electrical_conduit/zICsNI9x">conduit</a>, installation and repairs, crimping, pull-test requirements, and other operations that are critical to the production and function of cable harnesses. The standards mandated by the IPC differ based on a product's classification under one of three defined product classes.
These classes are: 

<ul><li>Class 1: general electronic products, for objects where the functionality of the final product is the major requirement. This can include objects such as toys and other items that do not serve a critical purpose.</li>
<li>Class 2: dedicated service electronic products, where consistent and extended performance is needed, but uninterrupted service is not vital. The failure of this product would not result in significant failures or danger.</li>
<li>Class 3: high performance electronic products, for products that require continued and consistent performance and where periods of inoperativeness cannot be tolerated. The environment in which these cable harnesses are used may be "uncommonly harsh." This category encompasses devices involved in life support systems or that are used in military.</li></ul>

<h2 id="references">References</h2>

<ol>
<li id="fn:1">"Cable Harnessing | Cable Harness | Cable Assembly & Assemblies". www.cableharnessing.co.uk. Retrieved 2019-04-06. <a href="https://chiran.cn.com//" target="_blank">https://chiran.cn.com//</a> <a href="#fnref:1" class="footnote-back-ref">↩</a></li>
<li id="fn:2">LeGere, Bob. "CABLE ASSEMBLY AND A WIRE HARNESS: What's the Difference?". www.iconnsystems.com. Retrieved 2019-04-06. <a href="https://www.iconnsystems.com/blog/cable-assembly-vs.-wire-harness" target="_blank">https://www.iconnsystems.com/blog/cable-assembly-vs.-wire-harness</a> <a href="#fnref:2" class="footnote-back-ref">↩</a></li>
<li id="fn:3">"Benefits And Applications Of Automotive Wire Harnesses". Miracle Electronics Devices Pvt. Ltd. 2017-03-28. Retrieved 2019-04-06. <a href="http://www.miracle.net.in/blog/benefits-applications-automotive-wire-harnesses/" target="_blank">http://www.miracle.net.in/blog/benefits-applications-automotive-wire-harnesses/</a> <a href="#fnref:3" class="footnote-back-ref">↩</a></li>
<li id="fn:4">Kobayashi, Masakazu, Yoshiya Hirano, and Masatake Higashi. "Optimization of assembly processes of an automobile wire harness." Computer-Aided Design and Applications 11.3 (2014): 305-311. <a href="#fnref:4" class="footnote-back-ref">↩</a></li>
<li id="fn:5">Bennington, Steve (6 February 2018). "Printing wiring harnesses and disrupting and industry or two". LinkedIn. Retrieved 7 April 2019. <a href="https://www.linkedin.com/pulse/printing-wiring-harness-disrupting-industry-two-steve-bennington" target="_blank">https://www.linkedin.com/pulse/printing-wiring-harness-disrupting-industry-two-steve-bennington</a> <a href="#fnref:5" class="footnote-back-ref">↩</a></li>
<li id="fn:6">"custom wire harness". Wiringo. Retrieved 2025-04-06. <a href="https://www.wiringo.com/" target="_blank">https://www.wiringo.com/</a> <a href="#fnref:6" class="footnote-back-ref">↩</a></li>
<li id="fn:7">"Helpful Guide of Wire Harness Manufacturing Terms, Tools and Tips". Falconer Electronics Inc. Retrieved 7 April 2019. <a href="https://falconerelectronics.com/tag/wireharnessmanufacturer/" target="_blank">https://falconerelectronics.com/tag/wireharnessmanufacturer/</a> <a href="#fnref:7" class="footnote-back-ref">↩</a></li>
<li id="fn:8">Hall, Nicole (2017-07-26). "Various Types of Wire Terminals When Building a Wire Harness". Falconer Electronics. Retrieved 2019-04-06. <a href="https://falconerelectronics.com/types-of-wire-terminals/" target="_blank">https://falconerelectronics.com/types-of-wire-terminals/</a> <a href="#fnref:8" class="footnote-back-ref">↩</a></li>
<li id="fn:9">"How Is a Cable Harness Designed?". Wirafe. 2018-10-29. Archived from the original on 2019-04-07. Retrieved 2019-04-06. <a href="https://web.archive.org/web/20190407004354/https://www.wirafe.com/how-is-a-cable-harness-designed/" target="_blank">https://web.archive.org/web/20190407004354/https://www.wirafe.com/how-is-a-cable-harness-designed/</a> <a href="#fnref:9" class="footnote-back-ref">↩</a></li>
<li id="fn:10">"Pull-test standards and methods". Mecmesin. Retrieved 2019-04-06. <a href="https://www.wireterminalstrength.com/pull-test-standards-and-methods" target="_blank">https://www.wireterminalstrength.com/pull-test-standards-and-methods</a> <a href="#fnref:10" class="footnote-back-ref">↩</a></li>
<li id="fn:11">IPC Product Assurance Task Group & WHMA Industry Technical Guidelines Committee (1 October 2022). "Requirements and Acceptance for Cable and Wire Harness Assemblies (Table of Contents)" (PDF). IPC. Retrieved 30 January 2025. <a href="https://www.ipc.org/TOC/IPC-WHMA-A-620E_TOC.pdf" target="_blank">https://www.ipc.org/TOC/IPC-WHMA-A-620E_TOC.pdf</a> <a href="#fnref:11" class="footnote-back-ref">↩</a></li>
<li id="fn:12">IPC Product Assurance Task Group & WHMA Industry Technical Guidelines Committee (1 October 2022). "Requirements and Acceptance for Cable and Wire Harness Assemblies". IPC. Retrieved 30 January 2025. <a href="https://shop.ipc.org/ipcwhma-a-620/ipcwhma-a-620-standard-only/Revision-e/english" target="_blank">https://shop.ipc.org/ipcwhma-a-620/ipcwhma-a-620-standard-only/Revision-e/english</a> <a href="#fnref:12" class="footnote-back-ref">↩</a></li>
</ol>

Cable harness open-in-new

Cable harness