Types of Wire Harness Components

Connector Wire Harness

Wire harnesses are collections of electrical wires, cables, and subassemblies covered by exterior sheaths that are used to connect devices to their power source. Their sheaths both protect the internal components from environmental hazards—such as physical damage and moisture—and organize them. The key components of wire harnesses include:

ㆍConnectors

ㆍTerminals

ㆍlocks

ㆍWires

ㆍcables

ㆍOuter coverings

When choosing a wire harness, it's essential to keep in mind the capacities of each component to ensure your devices are powered safely. The following article outlines the types of components typically employed in wire harnesses and their selection considerations.

Types of Wire Harness Components

There are several types of wire harness components, each of which is available in multiple variations to suit different applications. These components include:

ㆍWire: The wire carries the current or signal that powers a device. The wire's capacity needs to meet or exceed the voltage or bandwidth it's expected to transmit. Most wires are copper and can have a specially chosen coating.

ㆍConnectors: Wire connectors are available in several varieties and sizes to connect different types of wires. While they are usually plastic they can be made from a variety of elements including metal and ceramic.

ㆍFuses: Fuses stop surges of power from overloading or damaging devices on the receiving side of the fuse. Different harnesses use different classes of fuses. They are generally rated for 32 volts or less and vary based on their amperage rating.

ㆍGrommets: Grommets are insulators to keep moisture out of the connector.  A grommet can be attached with the terminal or can be a part of the connector.

ㆍOuter coverings/Insulators: Also referred to as tubes and sleeves, insulators provide some degree of abrasion resistance, environmental protection, and protection from electrical shock. They can be made of various materials such as nylon or polyolefin.

ㆍRelays: Relays turn higher amperage circuits on or off. This quality allows harnesses to power multiple things. Like fuses, they vary based on amperage requirements.

ㆍStrain Relief: Usually added to the outside of the connector.  It is designed to prevent the force of pulling of the wires in the connector which could allow the terminal to pull out of the connector making a bad connection.  Strain relief can also be added at extreme bend radius which again can put undue force on wire and the terminal inside of the connector

Terminals: Terminals are the metal parts that are attached to the end of the wire to be inserted into the connector or to be attached to a point on the connecting equipment.

ㆍTies: Cable ties and clamps keep the wires inside of the harness attached to from a stream of wires to a particular direction.  It can also be used to attach to a structure at fixed points to minimize movement.

ㆍLocks: Locks are inserted into the connector to prevent the terminal attached to the wire from being pulled out of the connector.  It can also assure complete insertion of the terminal into the connector.

Automotive Wire Harness

Industries Served by Wire Harnesses

Wire harnesses play an essential role in almost every industry. Some of the most common industries that use wire harnesses include:

ㆍAerospace

ㆍAutomotive

ㆍElectronics

ㆍHousehold appliances

ㆍManufacturing

ㆍRefrigeration

What to Look for in Wire Harness Components

When selecting a wire harness for a product or system, there are a number of factors to keep in mind. In addition to considering the working and environmental requirements of the application, industry professionals need to be aware of any applicable industry standards or requirements.

Qualities to Look for in Wire Harness Components

When choosing a wire harness, some of the component qualities to consider include:

ㆍType of wire (including material, length, and gauge)

ㆍSheath, conductor, and insulation material

ㆍVoltage and current capacities

ㆍOrganization of the assembly (especially orientation and EMI canceling design features)

ㆍEnvironmental capabilities (e.g., indoor/outdoor, resistance to moisture, chemicals, heat)

ㆍSafety certification (for all applicable safety and industry-specific regulations)

We are an auto wire harness supplier, please feel free to contact us if you need them!