Cable harness

A wire harness is transferred (energy) a bundle of individual cables, the signals (information) or work streams. The cables are summarized in a harness, for example, by clamps, cable ties, twine or hoses.

Production

The cables are combined into a harness on the design details on a special workbench or on a bed of nails ( mold board ) and clamped together. This only limited flexible tree is then installed.

Harnesses are assembled normally on the geometric and electrical requirements.

Despite progressing automation harnesses in the automotive industry will continue to be made ​​manually, which will remain so in the foreseeable future. This is largely due to the many involved movements, such as

  • The threading of cables or stranded in hoses or threading shrinkable sleeves,
  • Wrapping with cloth tape, especially at junctions of pipe runs
  • Termination of contacts to the leads, especially in so-called double stops ( two lines on a contact )
  • The nesting of hoses,
  • The fixing of strands with tape, clamps or cable ties.

These movements are obviously difficult to automate (eg robots). Nevertheless, these activities are quick to learn with low professional qualification. This manual production is still more cost effective than automation. For certain vehicles, such as the truck comes a wide variety of variants added (due to different configurations, and vehicle lengths ), which has a very small lot size (up to 1) result. Nevertheless, different variants are manufactured to the same form boards. Right here is man against the machine still at an advantage because he can (without " reprogramming " ) change in a short time in different variants. To reduce the number of variants, amounts of harness variants stages (stage harness ) can be summarized.

The prefabrication can be partially automated. This concerns, inter alia,

  • The cutting of individual lines ( cutting machine )
  • The partial loading of the plug housing with precontacted lines ( module )
  • Welding more pipe ends ( welding machine )
  • The twisting of wires.

Testing the electrical function of a wire harness can be carried out by means of a test bench. The bench is programmed beforehand with the data of the circuit diagram.

Economic benefits

Advantages of a harness against a wiring with individual lines:

  • The required space is optimized, reduced installation space.
  • The installation takes less time.
  • The probability that components are connected incorrectly, decreases.
  • The maintenance is facilitated.
  • A harness provides additional protection, eg against shock, abrasion and weathering.
  • By standardizing the process, the wiring is more economical.
  • The electromagnetic radiation (electromagnetic compatibility ( EMC) ) may be reduced.

Harnesses in audio engineering

The in audio engineering ( stage and studio ) common wiring harness for the transmission of audio signals is also called multi-core.

Harnesses / Harnesses in the network technology

In the network wiring Harnesses are typically adaption cables of a multi-fiber connector system such as the MPO connector, the existing 12 fibers on 6 duplex connectors such as LC or SC connector split.

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