Wire Harness Design

Making a Wire Harness Design

Whether you are planning a weekend DIY electronic project or an aspiring electrical engineer, it’s essential to know what makes an efficient wiring harness design. There are many things to consider when designing or drafting a layout for a wiring harness. It’s often composed of numerous parts that all serve a purpose in optimizing the performance of the device, equipment, or machinery it was made for.

By carefully planning and putting together all the necessary components, you can make the whole building process more efficient and effective. There are many factors to consider before you start designing and building a wiring harness like the environmental conditions of where you will place the unit. If you place it in an environment with high temperatures, for example, you should consider heat-resistant insulation for your wiring harness design.

The wiring harness design found in your car would never be the same as what is found in your computer. The terminals and connectors, for example, vary depending on the purpose and function of the machine. Drafting a layout is important so mistakes won’t be made and the possible risk of malfunctions can be eliminated pre-assembly.

Things to Consider for Your Wiring Harness Design  

Insulation- The outer tubing that wraps around the wires is called insulation. Determining the proper material that you can use for the insulation is very important especially in extreme temperatures. Silicone is known to be one of the most efficient materials when exposed to heat. Polyurethane, however, is efficient when it comes to low or cold temperatures. By simply utilizing the appropriate insulation material, you can prolong the longevity of the wiring harness as a whole.

Measurements- The length of your wires and cables are of course very important to consider when it comes to your wiring harness design. You should also determine the appropriate dimensions before you push through with assembly. This will make the whole building process more efficient and save you time and money on excess materials.

Color Classification- The main reason why a normal wire harness may contain multi-colored wires is for better identification and classification. By segregating and sorting the wires into different sets and colors, it can help you determine the function of each wire groupings and make the whole assembly process less confusing or complicated.

Proper Terminals and Connectors- Terminals and connectors come in different varieties. Each type of terminal or connector has its own unique function when it comes to rerouting and distributing the wires. Having proper knowledge about which variation to use will prevent any mistakes and can ensure optimal performance for the device the harness will be placed in.

Proper Component Locations- Much like what was mentioned before, organizing the components into proper locations can ensure that your wiring harness design will definitely work once tested. You should also consider where to properly splice your wires to avoid short circuits or any damages once the electrical current is running. Checking your wiring harness design for any misrouted wires and miscalculated splicing may save you a lot of time, money, and energy.

In conclusion, when trying to draft your wiring harness design, it’s important to note that proper labeling and clear measurements are essential. Making your design readable and clear even for a potential manufacturer is ideal. A schematic layout is always the best way to showcase your finished work.