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Heavy Vehicle Wiring Harness

What is Heavy Vehicle Wiring Harness

An essential component of any modern agricultural operation, heavy vehicle wiring harness ensures that electrical systems in trailers are functioning optimally, reducing the risk of downtime due to wiring issues. With superior performance and durability, the trailer wiring harness is the perfect choice for farmers and agricultural professionals who demand reliable and efficient equipment.Heavy vehicle wiring harness is a specialized wiring harness designed for use in agricultural trailers. Made with high-quality materials, this wiring harness is designed to withstand the harsh environments and operating conditions of agricultural settings.

Advantages of Heavy Vehicle Wiring Harness

Reliability
Wire harnesses provide a reliable way to transmit electrical power and signals between different components and systems in a vehicle, machine, or other equipment. A well-designed harness ensures that all connections are properly organized, protected, and functioning correctly, reducing the risk of electrical faults or failures.

Safety
Proper wire harness design can reduce the risk of electrical fires caused by improperly connected wires or other electrical faults. By bundling and protecting wires, harnesses prevent accidental contact with other components and reduce the likelihood of short circuits and other hazards.

Efficiency
Wiring harnesses can improve the efficiency of electrical systems by reducing the amount of time and effort required for installation and maintenance. By providing a centralized, organized way to manage electrical connections, harnesses simplify the assembly and repair process, saving time and reducing costs.

Reduces clutter
Imagine long lengths of wires stretched out over long distances, and compare it with a single wire harness neatly placed instead. Thus, a wire harness reduces clutter and makes the space look neat and organized.

Why Choose Us

01.

Our Factory

HARLINK is a leading provider of customized wiring harness and electrical solutions for various industries. Our company was established in 2007 by a group of experienced professionals with a shared passion for designing and manufacturing high-quality wiring solutions. Over the years, we have grown to become a trusted partner for manufacturers across the globe.

02.

Production Market

Our company's wiring harness products have achieved success in various regions and markets around the world. Our primary sales regions include Europe, North America, and other countries and regions such as the Middle East, South America, and Oceania.

03.

Product Application

Some of the main areas where our wiring harnesses are commonly used include engineering machinery, agricultural machinery, road machinery, heavy trucks, marine vessels, vintage cars, motorcycles, recreational vehicles, aircraft, medical equipment, special equipment, and vehicles. These applications cover various functions such as power transmission, signal transmission, control, and instrumentation.

04.

Our Service

After-sales support is an important part of our commitment to customer satisfaction. We offer technical assistance, training, and troubleshooting to help customers with installation and maintenance, and provide fast and efficient repair and replacement services for damaged or faulty products.

How Automation is Revolutionizing Heavy Vehicle Wiring Harness

Manufacturing
Manufacturing wiring harnesses has traditionally been labor-intensive and time-consuming, but automation is revolutionizing the industry and improving efficiency and productivity. Automation involves using robotic systems and computer-controlled machines to perform traditionally manual tasks.

One use of automation in manufacturing wiring harnesses is through automated wire-cutting and stripping machines. These machines can cut and strip wires with high accuracy and speed, reducing the time and labor required for these tasks.

The use of automated assembly systems is streamlining the production of wiring harnesses. These systems use robots and other machines to assemble wires, connectors, and other components into the final harness. By automating the assembly process, manufacturers can reduce the risk of errors and improve overall production efficiency.

Another way that automation is revolutionizing the manufacturing of wiring harnesses is through the use of data analysis and monitoring. Manufacturers can identify areas to improve and optimize production to reduce waste and increase efficiency by collecting and analyzing production processes and performance data.

Manufacturing Processes in Heavy Vehicle Wiring Harness

After the online two-dimensional drawings of the wiring harness are produced, the production process of the wiring harness needs to be arranged. The basic data from the drawings to the output process provide equipment and terminal production parameters for the development department, material consumption lists for the procurement department, and basic operating content for the production department. A good process can also be optimized in the process of wiring harness manufacturing, including process optimization, equipment optimization, process optimization, and process optimization. The general production process of custom wire harness is as follows.

Wiring Harness Manufacturing Process: Cutting
The cutting refers to the cutting and stripping of the original wire (coil or barrel wire) according to the process department's compiled process lines and tubes. When cutting, attention should be paid to following the requirements and not allowing negative deviations, confirming that the raw material specifications, models, colors, and sizes meet the requirements, and carefully implementing the process flow content.

Wiring Harness Manufacturing Process: First Assembly
The first assembly is for the preparation of crimping, usually including processes such as threading heat shrink tubing, rubber tubing, threading retracted plugs, threading waterproof plugs, and stripping three-core wire and two-core wire. Strictly following the operating instructions of such processes can explain complex situations according to the crimping process diagram. The cable wiring harness assembly process should be particularly careful, and the process engineer should be very familiar with the plugs and terminals. Special attention should be paid when assembling three-core wires. If the process requires cutting or using PVC full-encapsulation, the quality control points should be followed to prevent electric leakage or fire.

Wiring Harness Manufacturing Process: Crimping
Crimping is a way to use mechanical equipment such as a crimping machine to press the terminal and the original wire together to connect them. After crimping the terminals, some terminals need to be heat-shrunk. Heat shrinking means evenly baking the heat-shrinkable tube on the crimped bare wire or terminal until it wraps around the terminal or the exposed wire. Heat-shrinkable tubes can be divided into single-layer and double-layer types. Single-layer heat-shrinkable tubes are mainly used for connection on the busbar, while double-layer ones are generally used for riveting points. Their role is to protect and prevent electric leakage.

Wiring Harness Manufacturing Process: Pre-Assembly
Pre-assembly is to arrange the semi-finished wires that have been crimped and assembled according to the drawing or pre-assembly process, plug the protective sleeves, wrap them, mark them, attach the accessories, wrap them, and finally obtain semi-finished or finished products. The process operation instructions for this process should be compiled and executed, and the semi-assembly or full-assembly of the wiring harness product should be completed. It is necessary to pay attention to the quality requirements of one insertion, two listening, and three retraction when inserting the protective sleeves. The rationality of the pre-assembly process directly affects the efficiency of the final assembly. It also reflects the technical level of the process engineer. If the pre-assembly part is too few or the wire routing of the assembly is unreasonable, it will increase the workload of the hanging board personnel and slow down the speed of the assembly line. Therefore, the process engineer needs to summarize experience on the spot to formulate a reasonable process.

Wiring Harness Manufacturing Process: Assembly
Assembly is the operation following pre-assembly, and it completes the outer covering protection of the wiring harness, the insertion of the terminals, the wearing of the accessories, the winding of the marking points, and the bundling of the straps according to requirements. This step is the finishing work of the finished cable wiring harness, so each process needs to be manually operated, so it is very important to allocate the tubes required for this process and the pre-assembly process.Arrange the tubes required at the workstations according to the process to make production and process consistent.

Wiring Harness Manufacturing Process: Inspection
There are two types of finished product inspections: appearance inspections and electrical inspections. Appearance inspections include size measurements, check of damage to protective covers, check of complete accessories, and check of correct bundling of marking straps, etc. Electrical inspections mainly test the conductivity and air tightness of the wires. Only cables and wiring harness products that pass the inspection are allowed to enter the warehouse.

Heavy Vehicle Wiring HarnessTesting Methods

Low-voltage continuity test: Apply a certain current to the home appliance wire harness to be tested, measure the voltage value and current value at the end of the cable, and use Ohm's law to convert the measurement results inside the tester to obtain an accurate resistance value. Use this resistance value to compare with the resistance value set by the user to determine whether it meets the user's index requirements, and display the judgment result on the computer in the form of a clear message of "pass" or "failure" to inform the user.

Insulation test: After passing the low-voltage continuity test on the custom aircraft wiring harness, conduct an insulation test. During the insulation test, the tester applies a certain high voltage to the cable to be tested, and the other cables are connected to the ground wire to measure the current between the cables. If the current exceeds the current value set by the user, it is considered that the wire Cable failed. When the current value set by the user is satisfied, the insulation resistance value at this time is measured. The judgment result will be displayed on the computer in the form of a clear message of "pass" or "fail" to inform the user.

Withstand voltage test: Apply a high voltage to the 3d printed wiring harness to be tested for a certain period, and measure the current on the cable. If the actual current exceeds the current value set by the user, the cable is considered unqualified. The judgment result will be displayed on the computer in the form of a clear message of "pass" or "fail" to inform the user.

Composition of Heavy Vehicle Wiring Harness

The so-called heavy vehicle wiring harness means to bundle various wires with insulation materials, combine different colors and specifications of wires into one, making it more complete and unified, and also safer. The cross-sectional area of the selected conductor is 60% of the actual current-carrying capacity of the conductor for electrical equipment that works for a long time, and 60% to 100% of the actual current-carrying capacity of the conductor for electrical equipment that works for a short time. The cross-sectional area of the selected conductor is based on the load current of the automotive electrical equipment.

In order to easily identify the wires in each bundle, different colors and letters representing the color are used. Wire harnesses are generally assembled from plastic parts, terminals, wires, circuit protectors, rubber parts, supports, fasteners, and other accessories (including tapes and sleeves) according to certain process steps. If we make a Pareto chart based on the proportion of raw material costs for wire harnesses, then wire, plastic parts, and terminals are the largest part of the cost. The raw materials for wire harnesses are mainly purchased from outside. The main method of controlling raw material costs is to optimize the raw material costs of wires, plastic parts, and terminals through benchmarking and VAVE methods.

The Main Causes Of Heavy Vehicle Wiring Harness Damage

Insulator aging

During long-term use of the equipment, if it is often under poor heat dissipation or overload conditions, the wiring harness insulator will be more likely to age, causing cracks, and eventually the wiring harness cannot be powered normally. Therefore, it is necessary to improve the heat dissipation of the equipment or replace the wiring harness in time.

The insulator is damp

In a humid environment, the resonance and cracking of the wiring harness insulator during use will make it easier for water molecules to enter the interior of the insulator, causing problems such as moisture and corrosion of the wiring harness, and eventually cannot be energized. Therefore, in a humid environment, the insulation layer of the protective wiring harness should be strengthened in time or the wiring harness should be replaced.

Too high voltage

If the voltage is too high, the electrical layer of the wiring harness will be broken down, resulting in the failure of the wiring harness to be energized. At this time, it is necessary to check the voltage of the equipment and replace the damaged wiring harness in time.

Damage

During the use of the wiring harness, improper operation of the equipment by employees is also an important cause of damage to the wiring harness Such as excessive bending of the wiring harness, excessive stretching, and abrasion of the insulation layer are common reasons for the failure to power on normally. Therefore, in the face of man-made damage to the wiring harness, not only the wiring harness needs to be replaced, but also the replacement cost caused by improper operation needs to be reduced through management.

How to Choose Heavy Vehicle Wiring Harness Material

The quality of heavy vehicle wiring harnessmaterial directly affects the quality of wire harness. The choice of wire harness material is related to the quality and service life of wire harness. Remind you, in the choice of wiring harness products, must not covet cheap, cheap wiring harness products may be used is inferior wiring harness material. How to tell the quality of the wire harness is good or bad? If you know what the wiring harness is made of. Wiring harness is usually composed of wire, insulating sheath, terminal and wrapping material. Once you know these materials, you can easily tell the difference between good and bad wiring harnesses.

Material selection of wiring terminals
The copper used for the terminal material (copper piece) is mainly brass and bronze (the hardness of brass is slightly lower than that of bronze), and the proportion of brass is larger. In addition, different coating can be selected according to different needs.

The choice of insulation sheath
Sheath material (plastic parts) commonly used materials are mainly PA6, PA66, ABS, PBT, pp, etc. According to the actual situation, flame retardant or reinforcing materials can be added in the plastic to achieve the purpose of strengthening or flame retardant, such as adding glass fiber reinforcement.

The selection of wire harness wire
According to the different use environment, choose the corresponding wire material.

The choice of dressing materials
Wire harness dressing to wear resistant, flame retardant, corrosion prevention, interference prevention, noise reduction, beautify the appearance of the role, generally according to the working environment and space size to choose the dressing material. In the choice of dressing materials usually have tape, corrugated pipe, pvc pipe and so on.

FAQ

Q: What is heavy vehicle wiring harness types?

A: Some of the most popularly used wire harnesses are flat harnesses, ribbon harnesses, EMI shielded harnesses, RF harnesses, airborne looms, and military looms. You can choose to have a particular kind of wire harness, based on your application, and the required performance and stability.

Q: What is the purpose of heavy vehicle wiring harness?

A: The purpose of a wire harness is to organize individual wires into a single unit to efficiently transmit electrical power and signals. A wire harness reduces labor time and potential for human error, enabling technicians to fit complex wiring assemblies into small or hard-to-reach spaces.

Q: How much does heavy vehicle wiring harness weigh?

A: “The wiring harness is one of three heaviest subsystems in many vehicles—as much as 150 lbs in highly contented vehicles—and it's very typical for the average vehicle to have 100–120 lbs of wire harness in the vehicle.

Q: What is the difference between cable and heavy vehicle wiring harness?

A: The difference between cable assemblies and wire harnesses is that cable assemblies create a path from one point or circuit to another, while wire harnesses connect several points or circuits with multiple breakouts running in different directions, serving multiple functions with multiple terminations on each breakout.

Q: How do you measure heavy vehicle wiring harness?

A: Use a multimeter to measure the resistance between different points on the harness. A low resistance indicates continuity, while a high resistance or an open circuit indicates a problem. Insulation Resistance Testing: Insulation resistance testing ensures sufficient insulation between conductors.

Q: What are heavy vehicle wiring harness made of?

A: Wire harnesses consist of various components and materials in the manufacturing process. The most common elements include wires, connectors, terminals, and protective sleeves. Wires are typically made from copper or aluminum and are coated with insulation to prevent electrical interference.

Q: How many circuits do I need for heavy vehicle wiring harness?

A: An automotive wiring harness connects all of your car's electrical devices and components to a primary power source. Typically, basic wiring harnesses include a fuse block and a minimum of 8 to 12 circuits.

Q: Are all heavy vehicle wiring harness the same?

A: They're all pretty vehicle specific, models specific, and sometimes even submodel specific. You can have the same make model and year of car, but depending on the emissions they could have a different wiring harness or different portions of wiring harness.

Q: How long does heavy vehicle wiring harness last?

A: Vehicle makers bundle these wires together for easy installation and management. These bundles or harnesses have a protective covering and are routed in the whole car, so they do not get damaged with use. In most vehicles, a factory wiring harness can last a lifetime without causing any issues.

Q: What is the process of heavy vehicle wiring harness?

A: The process of producing harness wire consists in precise connection of cables with terminals and insulating elements in a way that allows current to flow from one point to another. This process may include connecting wires with connectors, soldering, gluing, crimping or using other methods of connecting wires.

We're professional heavy vehicle wiring harness manufacturers and suppliers in China, specialized in providing high quality customized service. We warmly welcome you to buy high-grade heavy vehicle wiring harness at competitive price from our factory. Contact us for quotation.

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