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No matter what industry you’re in, having a heavy-duty wiring harness that can ensure reliability and quality performance no matter what you put it through, is important. If you’re driving off-road, out in adverse weather conditions or have your machine or vehicle running 24/7, it’s even more crucial. While it may feel tempting to save money and go with a lower-quality option, this will likely cost more in the long run as you spend more time and money on repairs and replacements. At Harness Master NSW, we’re experts in ensuring your wiring harness has the durability to withstand whatever you throw at it.
Why Heavy-Duty Wiring Harnesses Are Important
Ensuring your vehicles and machinery have high-quality wiring harnesses is essential for a number of reasons.
Safety and Security
A heavy-duty wiring harness will often be more reliable and have improved longevity. This is important for ensuring your equipment doesn’t prematurely and unexpectedly fail. When equipment breaks down, this leaves you dealing with the cost of repairs and losses caused by downtime and can even be a serious safety hazard in certain situations. For example, if the electricals in a vehicle in remote conditions were to fail leaving the operators with potentially no working lights, engine or GPS system, this could put people in a potentially dangerous situation. If systems on an aircraft were to fail due to unreliable wiring, this could leave those on board in a potentially life-endangering scenario. Having a durable wiring harness ensures you can rely on your vehicles and equipment to get the job done without risks to anyone’s safety.
Keeping Commercial Competitive
When you install heavy-duty, high-quality wiring harnesses, you reduce the frequency at which you need to conduct maintenance or order replacement parts. With equipment and vehicles that can run for longer without interruption, even in harsh conditions, this lowers operational costs. With less money spent on parts and fewer losses from minimised downtime, high-quality wiring harnesses help businesses maintain reliable production and output.
How Harness Master NSW Crafts Durable Wiring Harnesses
There are a number of elements during the production and aftercare of a heavy-duty wiring harness that can help ensure its durability and reliability.
High-Quality Materials
When putting together a heavy-duty wiring harness, it needs to be made from high-quality materials that can withstand things like mechanical stress, high temperatures and chemical exposure. For example, choosing copper conductors provides high conductivity and durability, provided the copper is free from impurities and is insulted correctly against corrosion and oxidation. Tinned copper is another preferred material due to its corrosion resistance.
When looking at insulation, considering materials such as Thermoplastic Elastomers (TPE), Polytetrafluoroethylene (PTFE) or Cross-Linked Polyethylene (XLPE) are great options due to their flexibility and ability to withstand harsh environmental conditions. XLPE has great heat resistance, PTFE is used for high temperature applications and TPE is known for its flexibility meaning it can withstand harsh movements.
Quality Control
At Harness Master NSW, our team has strict and rigorous quality control measures to ensure our wiring harnesses can withstand whatever is thrown at them. Testing things like insulation resistance, electrical conductivity and mechanical durability can help to identify any potential issues and ensure they’re addressed during production, rather than become a problem once in use.
Optimisation During Design
Building a reliable heavy-duty wiring harness begins in the design phase. Considering things like connector selection, wire routing and protective sleeving helps to optimise the design to improve overall performance, durability and current carrying capabilities. Selecting the right high-quality connectors and protective sleeving (such as protective coatings or heat-shrink tubing) can help reduce mechanical stress (including temperature and vibration variations) and ensure durability against environmental factors. Proper routing ensures wires don’t experience mechanical stresses, resonance or excessive flexing which can diminish their lifespan.
Modular Approach
In some instances, a modular design can help to improve the reliability and durability of a wiring harness. This approach allows for individual parts to be easily replaced, avoiding the need to completely disassemble the harness. This helps reduce downtime and costs during maintenance and makes upgrading or modifying the designs simpler, which can help extend the lifespan of the equipment. It can also help minimise the risk of any faults occurring during repairs because of the simplified process.
Manufacturing Techniques
The way a wiring harness is manufactured affects the quality of the end product. Using automated production helps ensure precision of assembly, creating consistent quality and durability. Removing the potential for human error when stripping, cutting, crimping or soldering helps enhance the accuracy of production while improving efficiency and consistency, especially where a wiring harness needs to be made to exact specifications.
Regular Maintenance and Inspections
The longevity of any wiring harness, including more heavy-duty designs, is sustained by conducting regular inspections and maintenance. Having a schedule to check for any signs of wear and tear, corrosion or other issues, as well as ensuring all parts are still properly connected and in place, helps ensure the integrity of the wiring harness and can help prevent unexpected breakdowns or failures.
If any issues, such as cracks, abrasions or corrosion are noticed, it’s important to repair or replace the affected parts as soon as possible to prevent further damage or deterioration. At Harness Master NSW, we offer all our customers access to high-quality parts for replacement and servicing to ensure the long-term reliability of all our wire harnesses.
High-Quality & Heavy Duty with Harness Master NSW
If you’re after a heavy-duty wiring harness to withstand some of the harshest conditions, ensuring you choose a high-quality option that has been carefully designed, manufactured and rigorously tested will help ensure your equipment and vehicles are reliable and durable no matter what they endure.
At Harness Master NSW, our expert team has years of experience in designing and manufacturing the perfect custom wiring harness for your needs. Contact our team today to learn more about how we can keep your business and equipment moving, all ways.
