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Latest Innovations In Wire Harness Technology

by | Mar 31, 2023

Innovation is vital for a sustainable future as it adds value to existing systems. They make technologies more sophisticated and help businesses gain a competitive advantage in the market. Wire harnesses have evolved in securing wires and cables. They provide several advantages over loose wires or cables, including safety and durability.
Wiring harnesses systematically integrate wires or cables that transmit electrical signals or power within durable insulating materials such as vinyl, rubber, conduit, or a weave of extruded string. Braiding materials are the most recent development in the industry. They are developed and used in many automotive, military, medical, aerospace, communication systems, and electronics sectors. They are also used in low-voltage electrical systems in commercial and residential spaces. Also, they are referred to as the ‘Central Nervous System’ for many devices.

Violin Technologies is one of the Best Wire harness Manufacturers in India. Their capabilities include electromechanical assemblies, box builds, cable and wire harness assemblies, precision machined parts, and sheet metal and stamped parts.

Automation of harness design can be done by many harness design software applications available in the market. Many companies get their harness designs customized as per their requirements. As technology advances, it’s important to note that it will only partially replace the existing wiring systems.

Different steps involved in the manufacturing process of wiring harnesses are as follows:

1) Design: Electrical requirements are considered while designing wire harnesses. Customers may have them customized depending on different requirements and specifications based on their products and applications. Ultimately, the wires have to be bundled together to form the harness. Environmental and measurement constraints must be considered. Low-voltage and high-voltage wire harnesses can be manufactured based on the voltage/current requirements.

2) Prototype: If any improvements have to be made to the wire harness, they are checked in this phase. Prototype models help optimize the harness’s functional performance and efficiency through inspection. They help make necessary modifications and rectify errors before the actual or original model is delivered to the customer.

3) Production: Once the prototype passes the test, the harness is ready for production and assembly. This phase involves wire cutting, layout, stripping and connections, and assembly. Assembly automation can be done. But, in a few cases, harnesses are assembled manually rather than automated as it is more efficient and cost-effective.

4) Testing: After the assembly process, safety and quality testing, resistance measurement, and short-circuit testing are conducted on the harnesses. The final product can be shipped to the ordering company if all the processes are performed precisely and accurately. Testing is done to ensure that quality standards are met.

Violin Technologies has been a game changer as Wiring Harness Manufacturers over many years. We are the Best Wire harness Manufacturers in India. Our experts assist in the complete lifecycle from designing to testing and delivery.

Wire harness technology uses and applications

Innovations in Wire harness Technology

Wire harness technology has provided innovative solutions in the automotive industry, electric vehicles, autonomous driving, smart wiring systems, and e-mobility. Automation of wire harness manufacturing has been a big move in wire harness manufacturing companies. The automotive industry is on the verge of a major transformation with new technologies and the development of innovative products. Let us drill through the major advanced technology innovations in cable harnesses in the above areas.

Automotive industry

Vehicle emissions have a serious impact on the climate and environment. Electromobility is the electricity usage for commuting and is the future of the coming generations. It includes e-cars, e-buses, e-bikes, and e-trucks. Since the vehicle uses electricity to generate power, the CO2 emissions reduce drastically, and the environmental effect is minimized. The wire harness for an electric vehicle differs from the one used for the normal Internal Combustion engine models that generate power by burning gas and fuel.

In Electrical Vehicles, different components like sensors, actuators, and batteries are connected through wiring harnesses. They are the core of all the electrical connections in the vehicle and are used to transmit electrical signals, data or information, and power distribution. As new electronic components are added to the electric vehicle, more wires must be connected. Automotive companies are mainly focusing on optimizing weight and cost constraints. More wiring implies more weight for the vehicle, which will reduce the range of the vehicle.

As the complexity of the wiring systems to connect devices in vehicles is increasing, there is a need for more sophisticated wiring to connect devices. With new technology like Artificial Intelligence (AI) and IoT, vehicles have become more advanced in their functionality and operation. Significant changes have been made to the wiring harnesses to catch up with the rapid pace of ever-changing technologies and demands.

Automation is a major development in harness production. CAD solutions are also available for designing the harness schematics. Simpler harness designs that use lightweight materials that are less complex and cost-effective are manufactured to meet the intricacies. Space effectiveness is another factor that’s taken into account while designing. Downsizing the cable size is an effective way to combat space issues. Low-resistance power transfer is needed to control the heat of the wires. High-insulation materials are used to protect from short circuits.

Every electric vehicle has to undergo rigorous testing before it is released on the market and to the customers. Solar power electric vehicles are developed with photovoltaic cells to optimize electricity consumption. New technology also brings many novel safety redundancies to the electrical system.

Autonomous driving

The paradigm shift to autonomous driving is bringing necessary changes in the wiring harness to make it a safety-critical system. It is the capability to drive without human intervention using sensors, cameras, data, and artificial intelligence. Wiring systems are responsible for connecting devices, the transmission of power, and information for operating vehicles.

Automated wire harness manufacturing has picked up the trend in autonomous driving. Manual manufacturing is labor-intensive and error-prone when it comes to autonomous driving. Many wire harness manufacturing companies are focusing on developing automated solutions to deal with the challenges faced in autonomous driving systems. These challenges in the vehicle include breaking, steering, ventilation, and infotainment systems.

Automated machines are used for cutting, stripping, sealing, and crimping wires. The automated machine predefines the length of the wire for cutting. Semi-automated machines can be used for twisting, heat-tube shrinking, and splicing. Modules or small wire harness sub-assemblies are manufactured before the test phase by the Wire harness manufacturing companies. In the test phase of manufacturing, these modules are all added to a large assembly board where final assemblies are performed before delivering to the customers.

Innovation Initiative Wire Harness is an initiative to automate the wire harness joined by the OEMs, Machine and Component manufacturers, Software suppliers, and research institutions. It has a major role in the future of wire harness manufacture.

A Trusted Partner In Wire Harnesses Manufacturing

Violin Technologies has the best talent to assist you with your cable and wire harness assemblies. We are the Best Wire harness manufacturers in India. If you are searching for Wire Harness Manufacturing Companies, your search ends at Violin Technologies. Our team specializes in design, engineering, test development, prototyping, and manufacturing. It is an ISO-certified Wiring harness manufacturer with a state-of-the-art facility in Chennai, offering cost-effective, high-quality delivery worldwide.

Chaitanya | author


About the Author

Chaitanya Kummamuru is from the wonderful city of Hyderabad which is the capital of Telangana state in India. She is a Software Engineer with good work experience in testing and development, and has a ‘Bachelor of Technology’ Degree in ‘Electrical and Electronics Engineering’. As an ardent reader she developed an interest in building her vocabulary and also a penchant for writing. With this mindset she wanted to explore content writing. She is a very dedicated individual with regards to work and has been a high performer.