While the term cable assembly and wire harness are often used interchangeably, these are two distinct products that have different uses.
A wire harness typically consists of multiple wires within an exterior sheath. The exterior sheath is made up of thermoplastic or thermoset and does not offer too much protection from friction or temperature fluctuation. Wire harnesses, therefore, do not find extensive application in harsh and demanding environments. Cable assemblies, on the other hand, also have multiple wires covered by an external sheath, however the sheath is made up of heavy-duty material that can withstand environmental pressures. Explore the top difference between cable assembly and wire harness.
Below are some of the problems faced in cable assemblies and wire harnesses; and effective troubleshooting methods for them:
Common intermittent errors in cable harnesses and wire assemblies manufacturing process include:
These can be on account of a wide range of issues such as:
Despite all possible efforts undertaken to ensure there are no errors in cable assemblies and wire harnesses, inadvertent errors can still creep in. To avoid this, it is important to test the components thoroughly. Some of the common testing mechanisms include:
This ensures that the mechanical properties are tested to see that they meet the requirement of the application. Some of the mechanical properties to be tested include:
This primarily involves testing to see that the cable assembly or wire harness can withstand environmental conditions such as:
The electrical testing largely involves testing for:
Visual testing involves looking for all components and ascertaining if they are in good condition. Some of the aspects to watch out for, include:
This involves assessing the signals that the cable assembly or wire harness can carry. You also need to check for crosstalk and signal errors. Also, it is important to see if the use of connectors, filters etc. ensures that signal strength can be maintained.
A judicious use of both the troubleshooting mechanisms as well as robust testing practices will ensure that you do not face performance issues with cable assemblies and wire harnesses.
Being a leading PCB manufacturer from past over 40 years, Technotronix is providing wire harness and cable assembly services in USA. It ranges from simple to every complex cable and wire harness assembly with quick turnaround time. Technotronix is specialized in layout and assembling of custom and complex cable and wire harness assemblies to address the needs of customers. We cater to the wide spread needs of our broad customer base of varied industries like aerospace, defense, telecommunication, medical etc.
For more information, get a quick wire harness and cable assembly quote or contact us via email at sales@technotronix.us or call us on 714/630-9200.
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