How does wiring harness work
Due to our strict in-process quality assurance requirements, it is rare that one of our harnesses does not pass each of our post production tests.
However, if a wire harness does fail to meet a requirement, it is carefully reworked or scrapped if appropriate. Once a harness has passed our tests, an assembler performs a few final operations on it. This can include applying shrink tubing and putting protective caps on connectors if appropriate.
Then the harness is ready for packaging and shipment. A unique aspect of wire harness assembly at Rapport is that generally speaking, the same assembler performs all the required operations on a particular batch of harnesses. In other words, they take the wiring harnesses from one station to the next and complete all the work on the assembly.
We find that this personalized attention assemblers give to a group of harnesses results in extremely high-quality work. At Rapport, we produce cable and wiring harnesses using standard materials for general use, but we also offer customization services. In addition, we can strip, cut, twist or dye wire to meet your requirements. To complete your order, we offer labeling services using laser-printed sticky labels or heat shrink tubing and bind your product with zip ties or tie wraps as requested.
And, whether you are ordering another set of standard wire harnesses or working with us to produce a brand new customized assembly, you get the same attentive service and unwavering quality standards. Our full-service facility outside of Denver can create your wire harness assembly from prototype to final packaging, quickly and cost-effectively. The central challenge of wiring harness technology lies in designing cost-effective techniques for rapidly and accurately assembling these connections.
Developing new, innovative technologies and understanding efficient design principles have enabled Sumitomo Electric Wiring Systems to design, develop, and manufacture products the automotive industry wants.
First, we listen to our customers. We take the time to understand their vision, requirements and specifications — cost, size, performance, quality, and time to market. Then, we use our research and engineering know-how to develop solutions that are not only innovative, but also affordable. Most importantly, we draw upon our systems expertise to streamline the entire product development process, from concept to prototype to manufacturing and delivery. The wires needed for the harness are first cut to the desired length and labeled appropriately.
Next, the ends of the wires are stripped to expose the uninsulated conductor and fitted with any required terminals or connector housings. The wires and components are then assembled on the pin-board to the desired specification and then bound together. Wire harness assembly process is one of the few remaining manufacturing processes that is more efficiently done by hand, rather than automation.
This is due to the variety of processes that are involved in the assembly. These manual processes include:. Because of the difficulty involved in automating these processes, manual production continues to be more cost-effective, especially with small batch sizes. This is also why harness production takes longer than other types of cable assemblies.
Production can take anywhere from a few days to several weeks. The more complicated the design, the longer production time is required. However, there are certain portions of pre-production that can benefit from automation. These include:. The final step of the assembly process is to test the harness for electrical functionality. This testing is done with the aid of a pre-programmed test board.
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