What is the difference between a wire harness and a cable assembly?

Wire harness: A component of multiple wires or cables bundled in a specific direction and equipped with connectors or protective sleeves to protect the wires from environmental factors such as vibration or wear. Each wire in the harness can be color-coded or marked for easy identification and maintenance. It is usually composed of cables, insulation layers, sheaths, etc. The main function of a harness is to transmit electrical energy or signals from one device to another, achieving interconnection between devices.

Composition and characteristics of wiring harness

The wiring harness usually includes the following parts:

• Wire or cable: used for transmitting electricity or signals.
• Connector: Used for inline connection and disconnection between circuits.
• Terminal: Used to establish electronic or electrical connections, typically composed of metal or alloy.
• Protective materials: such as tape, zip ties, sleeves, sheaths, etc., are used to protect and secure wire harnesses.

Functional Features

• Transmission function: A wiring harness is a key component for transmitting electrical energy or signals between devices.
• Protection function: By using an insulation layer and sheath, the wire is protected from physical damage or environmental impact.
• Simplify wiring: Tie multiple wires together to reduce the complexity and space occupation of wiring.

Application areas of wire harnesses

Automotive industry

Automotive wiring harness is the main network component of automotive circuits, closely related to electronic control systems. It includes power lines and signal lines, which are used to drive actuators and transmit sensor input commands, respectively. With the increasing functionality of automobiles, the design and manufacturing of wiring harnesses have become more complex, such as the introduction of CAN bus configurations and multiplexing systems to reduce the number of wires.

Electronic devices

In electronic devices, wiring harnesses are used to connect various components and ensure the normal operation of the equipment. For example, in computers, household appliances, and industrial equipment, wiring harnesses are an indispensable component.

Communication system

In the field of communication, a wire harness is an important concept in traffic theory used to connect relay lines, switching devices, and control systems.

Production and testing of wire harnesses

The production of wire harnesses has strict process flow and quality standards, including steps such as wire cutting, wiring, PIN insertion or welding, and wire binding. The testing process includes electrical testing and full inspection to ensure that the conductivity of the wiring harness is 100% and there are no short circuits, open circuits, or misconnections.

Components and functions of cable components

Cable assembly: refers to the components used to connect and protect cables, mainly including connectors, joints, tail fibers, splitters, and cable markers. These components are widely used in electronic devices, communication equipment, and the power industry, with main functions including power transmission, signal transmission, and protection.

• Connector: Used to connect cables and electronic devices, achieve signal transmission, and facilitate insertion and removal.
• Connector: Connecting two cables, common types include terminal connectors, choke coil connectors, and power cable connectors.
• Tail fiber: connects fiber optic cables to fiber optic sockets for fiber optic communication.
• Brancher: distributes cable signals, commonly found in situations where there are multiple branches.
• Cable marking: Identify the type, purpose, and location of the cable, usually using labels, barcodes, or color markings.

Application areas of cable components

Cable components play an important role in power transmission, communication, data transmission, and signal connections between devices. They can effectively transfer electrical energy from one device to another, transmit data, audio, and video signals, and to some extent resist external environmental influences such as waterproofing and anti-interference. 

In short, wire harnesses are widely used in various fields such as mechanical equipment, automobiles, airplanes, ships, etc. For example, the car wiring harness is the nerve center of the vehicle's electrical system, responsible for connecting various electrical components. In these applications, wiring harnesses need to consider factors such as equipment layout, electromagnetic compatibility, high-temperature resistance, and vibration resistance. And cable components can withstand various harsh environmental tests and have a longer service life. They are usually used in outdoor environments or places with high temperatures, high humidity, and high dust, such as industrial automation equipment, power plants, and mines. In addition, cable components are also commonly used in some high-reliability systems, such as robots and heavy industrial machinery.