Assembling a wiring harness is a technical skill that anyone with an electrical background should master. However, it is not entirely impossible for someone outside of the electrical industry to learn how to assemble a reliable wiring harness. A harness is used in many industries such as manufacturing, automotive, military, and aerospace. It can also be found in almost any modern device or machine. That's why learning how to assemble a wire harness can come in handy, especially in household projects such as car restorations or appliance repairs.
Understanding the purpose of a wire harness is the first step in learning how to successfully assemble one. To put it simply, a wire harness is what transmits and distributes electrical signals through a machine or device. Typically, a harness is made up of hundreds or even thousands of parts that all work together to provide the amount of power needed to run a machine.
Each wire harness is unique and designed specifically for where it is intended to be installed. A car wiring harness is completely different from what you would find in a spaceship. Knowing the different parts of a wire harness can help you recognize them easily, regardless of the device or machine it has been placed in.
Planning to assemble a wiring harness yourself for the first time can become much easier with the right tools. Having the right hardware can also increase your productivity and the efficiency of your wiring harness. Here are some of the things you might need that are also commonly used by wire harness manufacturers today.
Crimping tools- Terminals are fundamental elements of a wiring harness. Crimping tools are necessary to achieve the perfect crimping of terminals and avoid any risk of malfunction. For manufacturers, the crimping process is often automated to make it more consistent.
Compression tools- Just like crimping tools, compression tools are necessary to prevent any short circuit or malfunction. It compresses the ends of connectors and terminals to ensure a uniform connection.
Ferrules- A ferrule is usually a metal or plastic ring that is crimped onto a wire to seal the connection to a terminal. They are also commonly referred to as eyelets or grommets in the industry.
Assembly tools- An assembly tool helps secure the cable ties in place when assembling everything. Assembly tools should not be taken for granted as they greatly organize the arrangement of conductors in a wiring harness.
Before getting your wiring harness project started, it's also important to consider your options. Remember that every harness starts with a design and it's up to you whether you'll take on the assembly process yourself or have a manufacturer assemble the end result. Asking a wire harness manufacturer for help can have many benefits as they can also help you with the design process. However, going through the design and assembly process yourself can hone your skills in electronics and may come in handy in the future.
