A cable and wire harness is a grouping of wires which route signals r energy to the devices which are away from the main harnesses. So, these work as sub-assemblies or an extension of the main harness. Wire harnesses are used to power several electrical devices ranging from domestic appliances to complex medical equipment, and more. They not only improve the performance of the equipment but also provide security against the adverse effects of abrasion, vibration, and moisture. Also, they offer optimized physical space and reduce the risk of electrical short as the wires are constructed within insulated materials. A wire harness assembly is often called a cable harness assembly, and these terms are often used interchangeably. This post gives step-by-step details about a cable and wire harness assembly. So, stay tuned.
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Wire harnesses bundle up different cables together using cable lacing, straps, cables ties, electrical tape, extruded string, or any of these combinations. Instead of using a single strand to bind multiple wires, wire harnesses group cables of distinct types and wraps them together with covering for robust protection against demanding environments. Each cable is wrapped individually in insulation material. Thus, one can pull out a single cable if required.
The purpose of wire harnesses is to make connectivity easier and help control power devices. They keep the systems organized by preventing cables from running all over the place. The following advantages of a wire harness assembly have contributed to its immense popularity.
The following are a few important steps that must be followed while assembling a wire harness.
It is the first and the most important step of any manufacturing process, and the same applies to wire harnesses. Depending on the individual application requirement, the manufacturer estimates how much wire would be required between each connection. A wire harness design heavily relies on what it is used for, and the material type it is subjected to during integration.
This is another important step in a wire harness assembly. The wire harness prototyping allows manufacturers to get their hands on the real-time version of the final product. This helps ensure the efficient performance of the product.
The cables should be cut to the exact length. This is an automated process that uses cutting machines to produce wires of precise length in a bulk quantity. Once you are done with wire cutting, it is time to expose these wires by stripping the ends of the insulation material.
At this stage, the prepared wires along with their connectors are gathered together and constructed into the harness. This should be done manually as each wire requires to be taped off, measured, and fed through the harness to ensure that distances match the exact design specifications.
Here, the functionality of individual wire harnesses is tested for all relevant specifications. Manufacturers carry out different types of tests such as resistance testing and continuity testing.
By now, you may have got an idea of what a wire harness assembly is. Although it is a time-consuming process for your big projects, it offers the best returns on investments, and hence is cost effective in the long run. Are you looking for wire harness assemblies for your upcoming applications? If that sounds yes, then you must consult a reliable, trustworthy industry player who will assist you throughout the process. With years of market presence and skilled employees, Creative Hi-Tech offers end-to-end solutions for cable and wire harness assemblies, PCB assemblies, and more.
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Synopsys Saber&#; is a solution of high-performance virtual prototyping tools for multi-domain power electronics design that consists of SaberRD, SaberEXP, and SaberES Designer. Saber allows an engineer to run complex simulations with varying component tolerances, generate best and worst-case results, and easily conduct &#;what-if&#; studies. Industry-leading accuracy lowers development costs by reducing the number of prototypes required.
SaberES Designer is a wiring harness tool for optimizing wiring layout, materials, and costs, and can be integrated with industry CAD systems. This software provides a solution for wiring harness design challenges to ensure data consistency, data integrity, and design validation. This solution, also called as the top-down &#;connected&#; design flow, is built on a single design ESD database shared by all teams, ensuring consistency across all parallel projects.
It allows designers to choose content and parts from approved libraries and databases, ensuring correct-by-construction design while integrating the systems. The extensive capabilities for design generation, validation, and multi-domain verification lead to higher design quality and better electrical system robustness. The top-down generative flow improves the designer&#;s productivity, saving resources and reducing TTM. The single, unified database addresses the lack of system integration in the traditional flow. By using approved parts and maintaining consistency, the integration process is much smoother. There is no &#;big merge&#; step where numerous issues are uncovered.
The top-down flow also makes it much easier to share an architecture platform and to create concurrent variations for individual design projects. The shared database represents a &#;200% design&#; in which all possible options for the electrical system exist. As designers work on a new project, they use assembly filters to create a unique product. This makes it easy to choose among the available options to create modular and composite wiring harnesses. The filters are reused throughout the development process, including generating netlists for circuit simulation, exporting data to a 3D MCAD tool, and generating the manufacturing outputs.
The database and flow are shared by a diverse group of users. In addition to the roles managed by designers, other roles include the librarian who maintains the symbols and other information in the company library, the administrator who controls which users can access and change which data, and superusers who can make fundamental changes in the architecture platform. The design flow must be highly customizable, including adding additional types of libraries and controlling data access to follow company and project policies. Superusers have a lot of flexibility in tailoring the solution to fit the needs of the other users. SaberES Designer can handle such complexity seamlessly and is the preferred wiring harness design tool used by for several OEMs.
The common database means that all changes are available to all users immediately. There is no need for time-consuming manual import or export and no risk of data corruption by external interchange formats. Informational messages about changes are sent to the users, who assess the impact on their specific areas of the design. Users are alerted when design updates are required.
The only way to avoid unpleasant surprises when physical prototypes are built is through verification using circuit simulation. The goal is to &#;shift left&#; the design process by identifying any issues at the earliest possible project stage. For SaberES Designer, the simulator is a built-in solution so that users can readily try out options and variant combinations. This improves circuit robustness and quality, and it also enables &#;what-if&#; exploration of the design space. Simulation can analyze far more design permutations than building and testing multiple physical prototypes.
This allows the designers to right-size the electrical system and load-balance across the wiring harnesses and electrical components. The built-in simulator supports the following:
The built-in simulator also supports transient simulations, variation and reliability analysis for robust design, and fault analysis to meet the requirements of the ISO functional safety standard.
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