Wire Harness Manufacturing Process - Detailed Guide

The demand for wiring harnesses is growing as the production of automobiles increases. Therefore we need to understand the manufacturing process of this key component in detail. As a professional manufacturer of wiring harness connectors and automotive waterproof connectors, let's talk about what are wiring harness assemblies and what are the benefits of their use.

What is a harness assembly?

Simply put, a harness assembly is a bundle of processed wires with a protective sleeve. Harnesses are important because they organize the wires for easy implementation. Harness connectors are used in a wide variety of appliances including but not limited to: automobiles, flight simulators, panel displays, heavy equipment, etc.

Advantages of LIZONE harness connectors

• High electrical conductivity, high heat resistance.

• Excellent waterproof capability.

• Ergonomic design, connector preferred.

• They help to optimize space.

• Customized to the needs of the device.

• Improve equipment safety.

JST-03R-JWPF-VSLE,Housing for Female Terminals,Wire Harness

Manufacturing process

Step-by-step guide to the wire harness manufacturing process.

1.Wire harness design

The manufacturing process begins, of course, with the design aspect. Harness connectors need to be custom designed for each product. It is also important to carefully select the components of the harness and pay attention to all specifications.

2.Prototyping

Since the harness plays a crucial role, it must be tested beforehand. This means creating a functional prototype so that the harness can be tested in its intended application. You can avoid costly mistakes.

3.Production and Assembly

There is little room for error in the production of wire harnesses, so all design specifications need to be met. It is important to remember that, despite a degree of automation, manual assembly still plays an important role in the harness manufacturing process. In addition, the advantage of manual production is its cost effectiveness.

4.Testing

Post-production is an important phase of testing, where each harness goes through a safety testing process. This is a crucial process as it ensures that the product reaches its potential. The harness needs to be checked for continuity as well as for construction and labeling.

Summing up

It is important to remember that the more detailed your documentation is, the fewer problems you will face on the assembly floor. Some of the information that should be provided to the contract manufacturer includes: detailed images of the connector and pin locations, wire list, bill of materials, assembly drawings, etc., and the manufacturer will be able to make some recommendations on how to terminate the wires, torque values for harness components and fasteners, etc.

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At LIZONE, we have many years of experience in manufacturing and assembling industry leading wire harness assemblies and automotive wire harness connectors. Equipped with state-of-the-art equipment and skilled personnel, we offer harness assemblies to meet your custom requirements. We welcome your inquiry and will provide you with perfect service.