What Is an Electrical Harness? An electrical harness is an integrated and systematic combination of wires, connectors and protection coverings that enable the transportation of electric current and signaling in various equipment and devices. Knowledge of electrical harnesses is valuable to the average consumer in Huntsville, Alabama and to all equipment operators and maintainers along the Gulf Coast and beyond. Understanding of electrical harnesses facilitates equipment maintenance and service decision making and helps in diagnosing equipment electrical issues. Wiring harnesses are engineered and used to route and integrate electrical systems in equipment. Routing and integrating electrical systems in equipment facilitates manufacture, install and service inspection of the equipment. Equipment electrical systems harnesses are protection covers for individual equipment electrical systems. Protection covers for individual equipment electrical systems prevent damage to individual equipment electrical systems caused by equipment operating environment. Equipment electrical harness systems are used in vehicles, aerospace equipment, boats, heavy equipment, consumer product equipment and devices.
Electrical Harnesses in Huntsville and Gulf Shores, Alabama Electrical harnesses play an essential role in the operation of vehicles and other forms of transport, watercrafts, aircraft and other means of transportation as well as industrial and household electric and electronic products. An electrical harness may comprise several thousands of individual wires and other components. It is not uncommon to find persons with little or no knowledge of electrical systems and wiring to be intimidated or perplexed when an electrical harness is mentioned. If you own and operate a motor vehicle in Huntsville, operate a watercraft or vessel in the Gulf Coast, operate industrial machinery or equipment or work on or with aerospace products, it is in your interest to understand electrical harnesses and systems to help you determine when there is a problem with an electrical system, devise maintenance strategies and determine when to seek the help of an electrical technician. An electrical harness serves the vital function of organizing and integrating electrical and electronic systems of products and equipment. It is especially useful in the manufacture and assembly of large and complicated systems and equipment. Electrical harnesses protect individual system wires and components from the environment and other agents that may impact the equipment and systems. Electrical harnesses are ubiquitous and can be found in all forms of transport and products, manufacturing and processing equipment, domestic appliances and electrical and electronic devices.
Alabama’s industrial diversity offers opportunities to implement electrical harness technology in several industries. In Huntsville, the technology can be incorporated in a variety of aerospace and advanced manufacturing applications. In Gulf Shores, the technology can be utilized in marine and recreational vehicles. This paper presents an overview of electrical harnesses. Information includes definition, function, types, signs of failure, and considerations when selecting, assessing, and replacing electrical harnesses. A. Definition and Function An electrical harness integrates and organizes electrical components of an apparatus. It allows the flow of electric current and/or control signals between components. Electrical harnesses function like the nervous system of a machine. Like a nervous system, electrical harnesses serve interconnectivity and integration function of a machine. B. Elements of an Electrical Harness Several elements of an electrical hress can vary based on the purpose and complexity of the system. Elements of an electrical harness can include: one or more wires, connectors, terminals, and/or sleeves. C. Signs of Failure Some common failure modes of electrical harnesses include insulation breakdown, loss of electrical continuity, and electro-mechanical failure. D. Considerations When Selecting, Inspecting and Replacing Electrical Harnesses There are a number of factors to consider when selecting an electrical harness for a particular application. Consideration must be made for the environmental factors that will impact the harness. Inspection and replacement protocols are implemented to ensure the integrity of electrical harnesses.
- What are Electrical Harnesses? An electrical harness is composed of several components, including wire, insulation, strain relief, brackets, and seals. These components are selected based on environmental considerations and expected service conditions. The components used in an automotive harness are different from those in a marine harness. Each component must be selected to withstand the stress and environment associated with its location on the harness. An electrical harness is more than wires bundled together. Each component must be carefully selected to meet the requirements of the application. 2. How Does an Electrical Harness Work? An electrical harness provides a path for electrical energy to operate components and systems of a machine. This is accomplished by organizing wiring in a harness to interconnect the controls and components of a system. Most systems use harnesses to interconnect a control or power source with the equipment operated or controlled by that source. A harness may also connect components that do not require a direct physical connection. Wireless data links may be used to interconnect components to provide control or operate equipment. Other systems may use mechanical controls to engage and operate equipment. A harness may incorporate mechanical links to interconnect systems, components, or equipment operated by that control.
Electrical harness systems perform a variety of functions. To start, harnesses deliver power. Power can also be transmitted via harnesses in the form of signals. Signals may represent conditions or commands and are often carried by sensors and switches. Moreover, harnesses can deliver control over circuit functions. Harnesses can also be designed to accommodate one or more communication circuits. Communication circuits can be used to connect remote devices. Additionally, communication circuits may be integrated into harnesses to control and communicate with integrated electronic equipment. High-current power circuits and low-voltage control circuits are incorporated into harness systems in an architecturally similar manner to communication circuits. Environmental conditions are considered in the design of harness systems. Circuit and system protection is also accounted for. What Are the Main Components of an Electrical Harness? Knowledge of components helps in analyzing the rationale behind the importance of harness systems. Harness systems are made up of a multitude of wires. Copper is the most common conductor. Each wire is insulated to avoid contact with other wires and to protect the harness system from surrounding components. Other considerations when determining wire characteristics include voltage and current.
Connecting wires of differing circuit requirements to components using connectors. Connectors may contain multiple contact points. Contact points may be made of plastic or metal. Automotive connectors utilize locking mechanisms. Marine connectors may include additional seals. Terminals are contact points made of metal and connected to wires. Other contact points made of metal may be connected to equipment. Terminals may be crimped or soldered to contact points. Lack of a secure connection may increase electrical resistance and create a hot spot. Many protective coverings may be used to prevent damage to wiring. Grommets may be used to protect wiring when it passes though openings. Seals may be used to prevent dirt and moisture from entering electrical connectors and enclosures. Clips and brackets may be used to secure the wiring harness in its designated location.
Mounting hardware helps organize wiring, prevents snagging, and reduces wear and tear. Reliability is essential for all electrical assemblies. There are several types of electrical harnesses. Each type is designed for a specific application. Automotive Wiring Harnesses are perhaps the most recognizable type of electrical harness. They connect sub-systems and components throughout vehicles. A single harness can span an entire vehicle. Modular design allows engineers to configure vehicles with multiple harnesses to meet specific needs. A harness that connects a vehicle’s engine can incorporate sensors, ignition coils, and electrical components that control the decomposition and introduction of fuel to the engine. A harness that services a vehicle’s instrument panel can incorporate switches and controls, displays, and audio and video components. Marine Electrical Harnesses connect and distribute electrical power to components and systems on watercraft. Marine harnesses contain electrical components that are similar to automotive harnesses. Marine environments accelerate the corrosion of electrical connections. Vibration can also damage connections.
Marine wiring harnesses are exposed to varying conditions, and therefore, should utilize materials and connectors specific to those conditions. Wiring harnesses used in the aerospace industry connect the electrical and electronic components of vehicles, ranges, and other means of transportation as well as interplanetary vehicles. These wiring harnesses may serve the following systems and subsystems: navigation, communication, control, monitoring, and display. Wiring harnesses may also be a part of the vehicle’s power distribution system. Because wiring harnesses may serve systems that support the safety and efficiency of the vehicle, systems and processes to ensure the integrity of the wiring harness are necessary. Other industrial wiring harnesses include those used to connect the electrical components of industrial machinery and equipment, material handling systems, and transport equipment. The environment in which an industrial wiring harness is installed may require it to be protected against the entry of dirt and moisture, as well as the negative effects of vibration and oil. Agricultural equipment is exposed to various environmental conditions and therefore requires wiring harnesses that are routed and protected to withstand such conditions. Household and commercial equipment contains electrical harnesses as part of their systems.
Appliance Harnesses: They allow the connection of various devices to an appliance control unit. Without an appliance harness, an appliance may not function correctly or may not function at all. What Are Electrical Harnesses? Electrical harnesses provide numerous benefits over separate wiring. For one, electrical systems become simpler and neater with less clutter. Individual wires may be arranged and combined in several ways to form a harness. Each way serves a path through which current may flow. Protection from environmental and service conditions may also be provided by harnesses. Harnesses allow easier identification and replacement of circuits and components. Harnesses do not necessarily guarantee safety of a system, and for a system to be considered safe, other considerations must be met as well. What Is the Difference Between a Wiring Harness and a Cable Assembly? A wiring harness often consists of several individual circuit wires which may be combined in a branching structure. Individual circuits may be connected to various electrical components. Cable assemblies often do not contain several individual wires like a harness. Cable assemblies are often used in electronic devices.
A cable assembly is made up of one or more cable(s) that are terminated or connected at various ends. For instance, an automotive engine harness consists of numerous conductors that distribute the circuits to several sensory and control components. An Ethernet cable is a simple assembly that consists of one centrally located cable that is terminated at both ends. Custom electric assemblies and harnesses are manufactured based on the requirements and specifications of a given application. A harness or cable assembly may be specified for a given application, based on several factors. These factors may include the environmental conditions, the number and types of connections, the kind of circuit protection, and the mechanical and physical constraints of the application. How are electrical harnesses manufactured? Production of electrical harnesses involves a series of steps. The first step is the electrical design. This design includes the selection of the component and circuit level details. Consideration is given to the voltage and current carrying capacity of the circuit, the kind and quantity of insulation, connection and routing of the circuit, and the physical dimensions of the harness. Wire cutting to the specified length is the next step in harness production. The final step is stripping of the insulation from the wire.
Step 4: Terminal Crimping The ends of the wires are prepared by crimping Terminal Crimps using the correct tools. Quality of the crimp is important, and an improper crimp may create resistance, produce heat, or result in an unknown electrical connection. Step 5: Connector Assembly Terminals are placed in connector housings in the correct arrangement. Step 6: Harness Preparation The wires are arranged in the order specified, and the harness is prepared in accordance with the design by the use of clips, protective coverings and sleeving, and/or conduit. Step 7: Verification and Testing After preparation, each harness is inspected and tested to verify that the electrical connections are correct, terminals and connectors are properly installed, and workmanship meets the required standard. Reliability of a harness may also require that certain procedures be followed, documented, and approved. Step 8: Use The harness is installed on the vehicle, boat, airplane, machine, or other product. A harness may also need to be installed to meet electrical and mechanical requirements of the product.
- Electric Harness Manufacturing in Huntsville, Alabama
Huntsville is Alabama’s leader for engineering and technology. These sectors are continually advancing and evolving with new innovations. The electrical and electronic systems for defense and aerospace technologies are growing in complexity and must be designed by engineers. Huntsville has a regional network for defense and space technologies, as well as information technology, biological sciences and advanced manufacturing. The principal facilities and organizations for these industries are located in or around Redstone Arsenal, Cummings Research Park and the Marshall Space Flight Center.
In response, several manufacturers of specialty wire and cable have opened facilities to provide harnesses and assemblies for testing and support systems, as well as other engineered structures. The aerospace and defense markets create the largest demand for specialty wire and cable. Not all electrical harnesses can be used in aerospace or defense applications. An aerospace wiring harness, for example, can provide the electrical interconnection for flight deck instruments and integration of other onboard system. http://everyelectricalcalculator.com its Free