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.