WHAT YOU NEED TO KNOW TO DESIGN A WIRE HARNESS
Wire Harnesses the manufacturing process. • UL rating (i.e., flame rating
Were Designed and When considered during and temperature rating) and
Manually Assembled the definition, requirements, insulation diameter
on the Fly or specification phases of • Wire end properties,
a project, harness design including cut type (e.g.,
Historically, wire harness
and assembly can be more blunt), strip requirements
design was addressed during
automated. (i.e., strip length and
unit assembly. If considered
tolerance), and coating (i.e.,
earlier in the design–build
Does Technology coating type, strip length,
process, change orders to
Change What You and solder type)
wiring and other components
Need to Know • Voltage and current
throughout the build often
to Design a Wire requirements
affected the spacing and fit of
Harness? • Signal levels
the originally planned harness
Despite the advancement • OEM specifications and/or
configuration. As a result,
of technology, there are still requirements
harness design and assembly
were rarely automated and many factors to consider in
designing a wire harness. Visualize the
often designed and manually
What do you need to know to Finished Harness
assembled on the fly.
design a wire harness? In this Identify and specify the
Advanced short white paper, we’ll review pin board or assembly
Technology Takes harness design considerations board. Ensure that all of the
Wire Harness and identify most of the necessary components of the
Design to Earlier specification requirements. harness will meet the required
Design Stages operating temperature or
Start with the Basics temperature rise from current
With the advent of integrated
First, start with the basics. flow when the harness is in
electrical and mechanical
For each harness, know the place.
design software and
automated tracking of change characteristics of the wires:
Organize the Details
orders throughout the design
and build processes, harness • Length, including length Next, consider the required
design has been incorporated tolerance treatments for both ends of
into the earlier stages of • Color each wire. For each wire
• AWG properties crimp, note:
WHAT YOU NEED TO KNOW TO DESIGN A WIRE HARNESS
• Contact part number for • Labeling • Are bundles long enough
each side (i.e., left and right), • Ties, taping, straps, lacing, to accommodate turn radii
ensuring that specified crimp sleeves, or conduit around corners within the
accommodates wire gauge, • Branching harness?
coating, and/or insulation • Locks or seals • Can the finished design keep
• Length requirement • Heat shrinking wire bundles intact and in
between contacts • Shielding place during unit installation?
• Pull test requirements
For each, specify label copy, Consider How the
For each connector, note: part numbers, sizes, types, Finished Harness
application positions, and Will Get to Assembly
• Connector housing shield terminations. Consider the harness’
part number, ensuring packaging requirements.
that specified housing Prevent Errors
accommodates wire gauges, Before They Occur • Will a harness be bundled
coatings, and/or insulation Next, consider identifying with each unit for assembly?
• Pin 1 designation possible assembly errors. • Will quantities of harnesses
• Pin out be bagged as a set?
• Color codes • Can any terminals be • Does the harness require
• Length requirement between polarized? Keyed? boxing or other special
connector and wire end • Does the harness design handling prior to assembly?
• Continuity test requirements have an appropriate
grounding scheme? Plan for
Consider Limitations • Is there any possibility of Substitutions
and Other crosstalk or signal/power Finally, whenever possible,
Requirements interference? specify generic harness
Next, think through the • Is there enough room in the components and determine
wire bundle routing in the harness for wire bundles to whether derivatives are
finished harness, especially run without interfering with acceptable. Any allowance
if the bundle will be exposed other components? for the most efficient sourcing
to abrasion, movement or • Are all wires sufficiently long of materials and for best-fit
vibration, shock, moisture, or enough to accommodate choices to be made during
traffic. Specify: service loops at termination? assembly can reduce costs
WHAT YOU NEED TO KNOW TO DESIGN A WIRE HARNESS
and production time.
Track All Changes
If harness design occurs early in the overall design process, ensure that all changes to wiring
during design finalization and throughout the build process are identified, tracked, and resolved
through the harness design. Update the bill of materials. Even the most minor change to a
single wire can affect the harness material requirements, configuration or layout and fit, tooling
requirements, and testing requirements. Expensive and time consuming changes can be avoided
when all changes are tracked and resolved through the harness design.
Contact Us
Harness design can seem daunting. It is an extremely detailed process, requiring knowledge
of the design intent, electrical or signal requirements and limitations, and of manufacturing best
practices. Contact us for more information about how to make your harness design process
smooth and trouble-free.
Cable Manufacturing & Assembly Co. Inc.
10896 Industrial Parkway N.W.
PO Box 409
Bolivar, Ohio 44612-0409
Toll-Free: (800) 586-8404
Phone: (330) 874-2900
Email: cmaoh@cmacable.com
