Most people don’t spend a lot of time thinking about the wire harnesses that are literally all around them.
In many cases, these wire harnesses are powering or carrying information to equipment we use every day at home or at our jobs. Since they tend to be hidden away, we often don’t realize how important the design and manufacturing process is to the proper function and safety of our equipment. Luckily, reputable wire and cable manufacturers take their processes very seriously.
At its most simple, a wire harness is a group of wires or cables that have been covered by an exterior sheath. In many cases, they also have their own coverings. In general, they are used to organize a wiring system as opposed to providing protection from factors that could cause damage to the wires.
Wire Harness Design
The first step to manufacturing a wire harness is to identify the problem it is meant to address. Each piece of equipment has certain electrical and geometric requirements. For example, wire and cable manufacturers may be required to design a wire harness that fits into a limited space and meets certain electrical safety requirements. At Meridian Cable, we like to gather as much information as possible at the beginning of the process to ensure the finished harness is tailored perfectly to each piece of equipment.
Assembly Process of Wire and Cable Harness Manufacturers
Once our engineers have a design in hand, we gather the components and begin cutting the wires to the appropriate lengths using a special wire-cutting machine. The next step is to strip the wires and fit them with terminals and connector housings. Then we set up a workbench or assembly board to the design specifications. An assembly board is a full-sized diagram of the harness that shows all components as well as their locations. Only then can we get to work assembling the wires into a harness…by hand.
Since there are many processes involved in assembling a wire harness, it is often more efficient for wire and cable manufacturers to complete it manually, especially for small batches. However, depending on the specifications and complexity of the design, wire and cable harness manufacturers may be able to automate some of the steps in pre-production.
Because safety is one of the most crucial considerations for any wire harness, assembly isn’t the end of the process for a reputable wire and cable harness manufacturer. It is important to put the harness through multiple safety checks. Not only are Meridian’s manufacturing facilities UL-certified, but we are also committed to designing only the highest quality products for each and every client.
No matter how simple or complex a wire harness, it must be safe and function as expected. By working with an experienced wire and cable manufacturer, you can ensure your finished wire harness is both safe to install and use, and meets all of your electrical and geometrical requirements. The team at Meridian Cable works hard to make sure all of our clients get a custom harness that fits their needs. Contact us when you’re ready to talk about your next wire harness project.