A cable harness, also known as a wire harness, cable assembly, wiring assembly or wiring loom, is an assembly of cables or wires which transmit signals or electrical power.
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There are various forms to bind a cable harness depending on its application. Sleeving or lacing is done in many cable harness technologies. Cable ties, electrical tape and straps are also used for various other uses. Many a times multiple bindings are used in tandem for added strength and security.
Readymade cable harnessesarecalled deemed cable assemblies. There are some assemblies which are used quite commonly, but cable harnessing can be offered as a service to tailor a specific assembly of cables for each and every application.
Cable harnesses offer many advantages over having loose cabling or wiring. By binding or assembling wires and cables together, the application instantly becomes safer, securer and easier to manage. The protective outer jacket, sheath or any other form of binding gives the array of cables more rigidity and therefore safeguards the wire assembly against the threat and the negative effects of abrasions, vibrations, breakages or moisture.
Cable assembly also helps in application and optimum utilisation of space and allows space for other applications plus reduces the total size of the operation. Binding the cables into a non-flexing assembly reduces chances of a short circuit. The outer sheathing also makes the internal cables of the cable harness fire resistant though this depends a lot on the material of the outer sheath.
Cable assembly is used in various industries across the globe. Due to its benefit , such as increased rigidity and less chance of short circuit, they are ideal for various applications and can be adapted to many different technologies and environments.
Cable Harnessare used in construction machinery, automobile industry, industrial lighting and control mechanisms. Cars, planes and spacecraft have a very high volume of wiring and cables. Cable Harness are perfect for optimum utilisation of space and also offering increased protection to the individual cables which are harnessed inside. In the case of aircraft, there can be miles of cabling which would cause a logistical nightmare without the use of cable harness technology. The process of fitting a cable harness is made much easier and installation is much quicker due the fact that there is only one cable to fit.
Ease of assembly makes it is possible to manufacture bespoke cable assemblies for nearly any electrical application. Cable Harness come in different lengths, diameters, wire ranges and in various resistant materials. The outer sheaths can resist UV rays, oil, heat, fire, moisture or cold and therefore the cable assembly can be used in different environments.
Many a times Cable harness are made of 100% recyclable materials and therefore are environmentally friendly. A wide choice of terminals and connectors are available for both the input and the output of electrical current, data and control.
Cable Manufacturers are working on creating the most effective harnessing systems for various industries viz., aircraft manufacturing, automation, oil, food, beverage, robotics and renewable energy. Cable harness assembly is manufactured according to geometric and electrical requirements. The wires are cut with specialised cutting machines. The ends of the cables are stripped to expose the core, which are then installed with the relevant type of terminals or connector housings. A proper marking is done to surface printing procedure.
Wires are compiled together and clamped onto a pin number board that relates to the specification, which creates the cable harness. If required these can be attached to a terminal.
Depending on the client's requirements, specific features can be included, such as low smoke halogen free properties, fire resistance, armour, flexibility and much more. Much of the process is undertaken using highly specialised equipment that allows automatic processing. The processes are elaborate and require set up. Processes such as routing cables through sleeves, inserting one sleeve to another, fastening strands along with tape, clamps or even cable scarves are a part of the manufacturing stage may require automatic and manual production. Where manual production is used, it may be considered as more cost effective than automation, as there are fewer technicalities involved.