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A wire harness is a collection of connectors, terminals, wires and cables that are arranged to facilitate the flow of data and power to electronic devices, modules and components throughout the system. Wiring harnesses help simplify the wiring of a device by reducing the number of cables needed, keeping necessary wires organised and protected from the elements and making the connection of various components easier.
Often wiring harnesses are custom-designed to ensure maximum performance and efficiency for specific applications and devices. Available in all shapes and sizes, the materials they are made from, the way they are configured, how they are used and the benefits they can have vary depending on the necessary application. If you’re not sure what might work best for your next project, here’s a quick rundown of the essential basics of wiring harnesses.
Types of Wiring Harnesses
Wiring harnesses can come in a variety of materials and configurations. The type of durable material required will depend on the surrounding environment where the harness will be installed. For example, if your wiring will be running in a more damp environment, a more moisture-resistant material like polyethylene would be the best choice.
When it comes to configurations, there are a few options to consider depending on your needs.
Point-to-Point Cable Bundles
This is the most simple type of wiring harness. All the cables are bundled and packaged together into a single harness using mesh jackets, tape or sheathing. Creating a point-to-point layout for simple and direct connection, these types of bundles are easily found in off-the-shelf options and can also be custom-made.
Bifurcated Cables
A bifurcated cable consists of a single connector with wiring splitting off into two destinations. This slightly more sophisticated type of wiring harness configuration is useful for mixing various connectors and receptacles across different circuit boards.
Wiring Harness Applications
Wiring harnesses can help solve a range of interconnection challenges, making them a useful product across a variety of different industries and even everyday products like household appliances, personal electronics and audio and visual equipment. If your industry relies on cable arrangements, wire harnesses can help to improve efficiency and keep personnel safe. No matter what industry you’re in, if you need a custom wiring solution, Harness Master NSW can help you build the perfect solution within industry standards.
Automotive
Whether it’s in the dashboard, under the hood or helping you light the way, wiring harnesses are a perfect solution for saving space and fitting into the small and awkward spots in your vehicle. They also help keep complex cable systems organised to allow technicians to easily identify and fix any issues.
Telecommunications/IT
Wire harnesses can be found in modems, routers, laptops, servers and a variety of other communication equipment. With these devices often being small, a well-designed system helps make all those necessary cables fit and stay organised.
Robotics
Without wiring, there is no power. Without power, robotics and other automated equipment can’t run. Having wiring harnesses that safely organise, protect and route critical components ensures the efficient operation of this futuristic technology.
Medical
Hospitals and medical facilities rely on the dependability and efficiency of life-saving equipment. From dental equipment and crash carts to crucial diagnostic and imaging machines, having reliable, organised and protected wiring ensures this vital technology is always ready for use or can be quickly fixed if it malfunctions.
Aerospace
Even all the way up in space a reliable wiring harness is important. Satellites, aircraft and drones are just some of the important aerospace products that need a well-organised and dependable cable assembly to help facilitate the transmission of power and communication for vital space operations and activities.
Manufacturing
Whether it’s drilling, packing or quality testing, there a plenty of powerful machines that rely on a good wire harness system. Vital for both internal and external configurations, to keep that production line moving, a reliable and easily fixable setup is key.
Construction
Whether it’s for the machines and tools completing the building or the structures under construction, a simple and efficient wire system is crucial. Secure insulation and effective organisation can help keep a project running smoothly and to schedule and ensure the final build is safe and reliable.
Benefits of Wiring Harnesses
From reliability and safety to reduced installation times and costs, the benefits of ensuring your equipment has well-constructed wire harnesses speak for themselves.
- Create a safer working environment by ensuring there are no loose or scattered wires that could become a hazard, improve available working space and minimise the risk of damaged or tripping wires and cables that can become fire hazards.
- Avoid the need for multiple individual assemblies, helping to decrease costs.
- Reducing the number of connections and components needed in the system for decreased installation and maintenance time and costs, even for more extensive network setups.
- For systems that rely on hundreds of meters of complicated cables and wiring, improved organisation can increase efficiency and minimise downtime when issues arise.
- Protect against outdoor elements or indoor moisture exposure that can quickly degrade systems and equipment.
Ready to Get Connected?
A well-constructed wiring harness is important for so many different aspects and applications in our daily lives. Whatever the industry, whatever the challenge, if you need a custom cable solution, the team at Harness Master NSW are here to help you build the perfect solution. Contact us today to discover how we can help keep you moving, all ways.
