About wire harness and cable assemblies, everything you need to know

Wherever there is a complex electrical system, there is a wiring harness or cable assembly. Sometimes called cable harnesses or wiring assemblies, these units are used to organize, consolidate and protect electrical conductors. Because wire harnesses are custom designed for their application, they can significantly improve the efficiency of a system.

What is a wire harness?

Simply put, a wire harness is a bundle of cables and wires and the components used to wrap, support, and organize them. These elements include tapes, sleeves, and ties that hold the cable in the best position for transmission. Wire harnesses are designed to meet the electrical and geometric requirements of an application and are used to simplify connections to more significant components.

What is the purpose of wire harnesses and cable assemblies?

Wire harnesses solve many of the challenges associated with electrical systems. By combining many individual wiring elements, they make it easier to connect and assemble complex systems. At the same time, they provide additional protection for wires and cables against unwanted bending and the environmental impact of insulated harnesses.

This combination of advantages means that wire harnesses and cable assemblies can be used in various applications. Most manufacturers have found that combining electrical components in a harness is a cost-effective way to improve performance while simplifying installation. Uses can be found in industries ranging from aerospace to residential wiring.

Application areas for wire harnesses and cable assemblies

Aerospace

Aerospace equipment typically includes dense bundles of cables and communication cables. Wire harnesses are used for power transmission to aircraft engines, satellite data transmission, and similar aerospace applications.

Automotive

The automotive industry extensively uses wire harnesses and cable assemblies, including gasoline and electric vehicles. In these cases, wire harnesses are essential to save space and ensure wires are installed around mechanical components. Organizing conductors is also essential to keep different systems separate under the hood for efficient operation and easy maintenance. Automotive systems that use wiring harnesses include lights, turn signals, displays, etc.

Medical

In hospitals, clinicians must be able to establish reliable connections quickly. In many cases, such as when setting up critical care equipment is a matter of life and death. Wire harnesses enable these quick links and ensure patient safety. Other medical applications include more permanent devices, such as imaging equipment and dental chairs.

Telecommunications

Telecommunications systems can include tens to thousands of cables, all of which must be organized to save space and be easily identified. Components fill this role, bundling cables for modems, routers, and similar communications devices.

Information Technology

Within IT, wire harnesses are used at all scales. Wire harnesses and cable assemblies save space inside small laptops and organize thousands of cables within a network facility.

Construction

Safe and efficient wiring powers residential and commercial buildings. Builders rely on harnesses to insulate and organize wires that meet all relevant codes.

Manufacturing

In manufacturing environments, stray wires represent a significant safety hazard. At the same time, many machines include extensive wiring, including CNC units, 3D printers, and traditional workstations. Wire harnesses ensure facility safety by including wiring and ensuring reliable connections.

Robotics and Automation

Robots of all sizes require organized and durable cabling to function correctly. Often, space is limited, so wire harnesses are needed to route and contain circuits.

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