Considerations Before Designing A Cable Harness - Miracle Electronics

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Considerations Before Designing A Cable Harness
- Miracle Electronics
When designing any new product, engineers tend to
focus mainly on its features, functionalities,
and cost. In the process, what they forget is to
think about the wiring until the last stage. In
fact, engineers need to put their thoughts into
the various elements of wiring like wire length,
bending radius, and routing. As a matter of fact,
engineers tend to make several mistakes while
designing cable harnesses, some of the most
common ones mentioned below.
Mistake 1 Cutting the wires too short that tend
to scrap the entire cable harness. Mistake 2
Failure to control and translate the analytical,
functional, and commercial requirements of the
harness into connected product lifecycle
management methodologies and workflows. These
include all kinds of design elements,
manufacturability, product variation, mass
production, and customer demand. Mistake 3 Not
carrying through the initial design intent as far
as connectivity definition is concerned. Mistake
4 Lack of standardization in design and
manufacturing criteria, which ultimately result
in huge financial costs. To avoid the above
mentioned mistakes, and any other mistakes for
that matter, it is important that you make a few
considerations when planning for cable harnesses,
one of the most crucial
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parts of your equipment, so that you can
contribute to more efficient processes with more
effective results. Also, you need to work with a
reputed and reliable electrical supplier to
determine the best way to handle designing of a
cable harness. This means that you must approach
Miracle Electronics, one of the most well-known
cable harness manufacturers in India, who can
help identify your options and develop a solution
precisely aligned to your needs. Environmental
Considerations Out of the multiple numbers of
factors to be considered for the designing of
cable harnesses, environmental factors are the
most important ones. For example, some harnesses
are exposed to extreme temperatures like those
routed near the engine or exhaust. On the other
hand, there are other harnesses that are exposed
to water, chemicals, oil, or dirt. Another
environmental factor to consider is exposure to
abrasion for which the harnesses need to be
flexible. Therefore, selecting the right kind of
cable harness is important, or it may lead to
failures, safety concerns, and insulation
breakdowns. Design Considerations First of all,
you need to be very clear regarding the
dimensions and tolerances. Next is the type of
covering required including tape, woven, split
sleeve, or conduit. All these coverings have
different purposes and pros and cons.
Understanding all this is important to determine
the best covering for your particular
application. Next comes wire coloring and
labelling. You need to mention your preferred
wire colors and text that you want printed or
labelled on your wires to help identify circuit
names. Also, note all other kinds of labelling
that you require on your harnesses. Other
Considerations Other considerations that are
important for your cable harness design
procedures involve the type of wires, splicing,
terminals, connectors, etc. There are many
different types of wires with variations
including insulation material, plating, voltage
ratings, etc. There are also many different
types of seals, terminators, and connectors.
Different connectors accommodate different
types of seals and terminators, specific to
different wire gauges, wire insulation
thicknesses, and terminal plating. Testing The
last and very important step is testing the cable
harness. Use various testing methods like
passing a high voltage test, continuity test,
etc. For more details, please visit Miracle
Electronics