Here’s 3 Industries Which Rely On Custom Wiring Harnesses

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With the continued and rapid advancement of technology, the need for reliable energy and data transmission is more critical than ever before.

As a result, the use of custom wiring harnesses has become more and more necessary across a wide range of industries.

Some wiring harnesses may be as simple as two wires with a connector on each end. But for more complicated applications, the harness design can become extremely complex, branching out in several directions.

Whichever the case may be, wiring harnesses are an important component in many different types of projects.

With over 30-years experience in the industry, QCC Custom Cables are experts at designing and producing custom made harnesses, tailored to the needs of a specific industry.

In this blog post, we’ll take a look at some of the typical industry applications for wiring harnesses.

Custom Wiring Harnesses For The Automotive Industry

It can be argued that wiring harnesses are most often associated with cars and trucks and it’s easy to see why.

If you were to lay out all the wiring and cables required for an average car, it would stretch out for kilometres.

These wires and cables are essential for running the engine as well as operating the power windows, lights, navigation system and much more.

But there’s not really that much spare space inside a car to fit in all that wiring and cable.

This is why wiring harnesses are so important in the automotive industry. They are essential in organising individual wires and cables as well as keeping everything as compact as possible.

Wiring harnesses also provide protection against vibration and the hot parts of an engine. Without this protection, the wire and cables would be prone to damage.

Additionally, hiding wires out of sight is of key concern in the show car scene. People who restore classic and vintage cars often use highly customised harnesses to make sure their prized vehicles always look show ready.

Equally important is the design and manufacture of a “secondary” custom wiring harness when adding modifications or customising any type of vehicle. For example, if adding additional electronic devices and lighting such as reversing cameras, light bars, mobile phones, aerials, etc.

These devices can usually run off the vehicles current power sources but the wiring harness should be designed to integrate with the manufacturers harness and maintain the same quality and specifications. This will ensure that the new devices work seamlessly and not cause any issues with the existing equipment.

Military Uses For Custom Wiring Harnesses

The military has some of the most complex cabling and wiring requirements in the world.

Military vehicles in particular require complicated wiring harnesses which are specifically designed to meet stringent protocols and exacting specifications.

These harnesses need high levels of protection against intense conditions such as severe vibrations, high winds, extreme temperatures and water intrusion.

But it’s not just vehicles in the military that use custom wiring harnesses. Remote communication infrastructure and confidential data systems also require complex wiring and cable solutions.

The military even has its own set of standards for wires and cables called “mil-spec”. Mil-spec is an alphanumeric combo given to every component and part used military planes, tanks, radios, weapons etc.

The grading is used by the military to standardise their equipment and ensure every single component used is extremely robust.

Mil-spec wires and cables are used not only in the military, but other industries such as automotive, health and communications as a means of ensuring the robustness of equipment.

So if a wiring harnesses is graded as mil-spec, you know that it’s been built to last.

Wiring Harnesses Are Vital For Medical Equipment

There are few industries whose wiring and cabling needs are more challenging or more critical to human life than the medical industry.

Medical equipment is designed and built with the knowledge that if the equipment were to fail, a life could be lost. Therefore, it is essential that any wiring harness used in a piece of equipment is of the highest possible quality to ensure no failure can occur.

MRI machines, X-rays, medical sensors, ultrasounds and even electronic beds all require custom made wiring harnesses which will guarantee performance and ease of use. The more complex the machine, the more complex the harness becomes.

The choice of sheathing is incredibly important in order to eliminate the risk of dust or water ingress. Specialised protection must be incorporated into every medical harness design such as waterproofing, resistance to high temperatures as well as the ability to withstand repeated sterilisation.

Teflon or Silicon sheathing is often preferred in the medical industry as it’s a robust material which does not support bacteria growth and has higher tear strength than most thermoplastic (PVC) options.

Additionally, each component of a harness (the wires, cables, interconnects, terminations, etc.) must pass strict industry-specific compliance tests.

To Wrap Things Up

So as we’ve discovered, wiring harnesses are incredibly important across a diverse range of industries.

Each industry presents a unique set of challenges that must be taken into account when designing a harness.

The expert team at QCC Custom Cables understand these unique challenges and have over 30 years’ experience working on all kinds of projects.

If you require custom wiring harness, we have the right expertise to deliver a workable solution for you, in full and on time.

For more information and advice, simply click here to get in touch.

What Is A Custom Wiring Harness And What Does It Do?

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Custom wiring harnesses are a critical component in everyday electrical systems. They keep our cars running, our laptops powered and our washing machines spinning.

They are also widely used in more complex applications, such as airplanes, communications systems and military equipment.

But what exactly is a wiring harness?

With over 30-years experience in the industry, QCC Custom Cables are experts at designing and producing custom made harnesses.

In this blog post, we’ll take a look at the basics of custom wiring harnesses, what they are used for and how they are made. And, because we are “custom wiring harness” people, we’ll also share some insights into the work we do to help our customers get the results they are looking for.

First Things First

It’s important to note that the term “wiring harness” is often used interchangeably with other terms like wiring loom, cable harness and wiring assembly. All are essentially the same thing. Different industries have used different terms over the years.

However, there is a clear distinction between a wire and a cable. These two terms are again sometimes used interchangeably. But they really shouldn’t be.

A wire is a single strand of material, such as aluminium or copper, which conducts electricity.

A cable on the other hand consists of two or more insulated wires that run together inside a sheath. The wires inside of cables can be bonded, twisted or braided together.

Here’s The Basics Of A Wiring Harness

Without getting too technical, a wiring harness consists of an exterior sheath that covers an assortment of wires and cables.

The purpose of a custom wiring harness is two fold:

  1. To neatly bundle up wires and cables in order to keep an electrical system organised.
  2. Protect the wires and cables from damage

A wiring harness will also consist of various terminals and connectors which are attached to the wires at every exit point which connect in to other wiring harnesses, or devices such as sensors, fuses, lights and motors.

The sheath is often made from a type of thermoplastic called PVC, but can also be made from more heavy-duty materials such as corrugated conduit, wire braiding, expandable braiding, PVC tape or even different types of metal braiding.

The purpose of a wiring harness is to transmit power and/or electrical signals within a machine, vehicle, communications system or electronic device. The harness effectively “connects” a variety of components within an electronic system.

Think of a wiring harness as a bit like the human circulatory system.

How Is A Custom Wiring Harness Made?

Wiring harnesses can be made by hand or by machine. In most situations, a combination of both approaches is required.

For complex designs, manual intervention can be quicker than calibrating a machine to do the same work. However, it’s always ideal to automate where appropriate.

As volume increases, machines are used more and more to achieve economies of scale.

The process of making a harness begins with cutting the required wires to the appropriate length using a special wire-cutting machine or by hand using specialist tools.

The next step is to lay the wires out using a Harness Assembly Drawing. This is done to show how each wire is routed from one end point to another. Once all the wires have been routed, they are grouped together using cable ties, straps or tape.

Wire termination comes next. This involves stripping the insulation away to expose the core of each wire, then crimping on the terminals where specified. The wires are then inserted into sheathing and the appropriate connectors are fitted to the terminals.

Before a wiring harness can be used, it must be thoroughly tested. Highly sophisticated testing machines are used to test for continuity, short circuits, intermittent faults and insulation resistance.

If the harness passes all the necessary tests, it’s ready to be used in its intended application.

To Wrap Things Up

So as we’ve discovered, custom wiring harnesses are incredibly important component in many different electronic systems.

If you have a project that could benefit from a custom wiring harness, call the team at QCC Custom Cables.

We have the right expertise to deliver a workable solution for you, in full and on time.

For more information and advice, simply click here to get in touch.

5 Benefits Of Using Custom Wiring Harnesses

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With the continued advancement of technology, the use of custom wiring harnesses has become increasingly beneficial across a wide range of industries.

A crucial part of any electrical component, harnesses play an important role in keeping electrical systems organised as well as providing the necessary protection to the cables and wires.

With over 30-years experience in the industry, QCC Custom Cables are experts at designing and producing custom made harnesses.

In this blog post, we’ll take a look at 5 major benefits of using custom wiring harnesses.

And, because we are “custom wiring harness” people, we’ll also share some insights into design features of a well-made harness.

 

Saves On Time

Time is a highly valuable resource in any industry.

If a piece of equipment breaks or an electronic system goes down, you want to be able to quickly diagnose the problem and get it fixed.

It can be extremely frustrating and time consuming to have to sort through a jumble of unorganised wires and cables when trying to get something up and running again.

A custom wiring harness with systematic bundling makes it fast and easy for technicians to trace the cause of a failure to its source.

Well designed wiring harnesses will feature different coloured wires with clear labels to make the process as straight forward as possible.

Harnesses are also quick to install, easy to manage and help to avoid time consuming connection errors.

Saves On Space

A custom wiring harness minimises the length of essential cables and wires, therefore optimising the most efficient use of space possible.

Imagine, for example, if you were to take out all of the wiring from an average car and lay it out on the ground. The wires and cables would stretch on for many 100’s of metres in most cases.

The use of wiring harnesses keeps everything as compact as possible. Without them, it would be impossible to fit all of the necessary wiring inside of the vehicle.

It’s not just the automotive industry that relies on wiring harnesses to maximise the use of space. Telecommunications, defence, aeronautics, marine, robotics and manufacturing industries are all dependent on harnesses in minimising the amount the space taken up countless wires and cables.

Premium Quality Materials

There is a huge difference in quality between store-bought cables and wires compared to the materials used in a custom wiring harness.

A reputable harness manufacturer will only use premium grade, robust materials to ensure the highest calibre of signal and power transmission is achieved.

In addition, custom wiring harnesses undergo stringent testing procedures to ensure ultimately reliability and wiring performance.

Protection And Safety

When wires and cables are bundled together into a custom wiring harness, they are better protected against the adverse effects of moisture, vibrations and abrasions.

An array of tailored protection measures can be incorporated into the design of the harness depending on its intended use and operating environment.

For example, thermal management sleeves can be used to provide superior fire resistance under extreme conditions. Whereas a braided covering is water resistant and will allow liquid and moisture to pass through in the event of direct or indirect exposure to water

Moreover, as the wires and conductors are bundled together, they are much less likely to short-circuit compared to a collection of loose wires that may catch on parts of the machinery they are being threaded through.

Custom Solutions  

Last but certainly not least, a custom wiring harness provides a completely bespoke solution for a specific problem or application.

An experienced harness manufacturer will have the capabilities to meet your detailed performance specifications.

The individual operating conditions of your harness will be considered in detail to ensure the right types of materials are used and ample protection measures are incorporated into the design. This will ensure your harness stands the test of time, thereby adding value to your project.

Additionally, a manufacturer can work with you to pinpoint new ways to save you time, effort and money with an optimised harness design.

To Wrap Things Up

So as we’ve discovered, custom wiring harnesses offer significant benefits across a wide range of industries and applications.

The expert team at QCC Custom Cables have over 30 years’ experience designing and assembling harnesses of varying size and complexity.

If you require a custom made harness, we have the right expertise to deliver a workable solution for you, in full and on time.

For more information and advice, click here to contact QCC Custom Cables.