Wire Harness Processes

Tip:

See the Wire Harness Process Group documentation in the Cost Model Guide for more details.

There are 8 top-level processes in the routing of the Wire Harness Process Group.

• Wire Termination is the process performed to the end of a wire (or cable) that allows it to connect to a device (connector, switch, terminal, and so on). Wire Termination includes:

  • Wire Marking: the process of printing important information on wires.
  • Manual Crimp: the process of manually crimping the contact onto the wire.
  • Machine Crimp: the automated process of connecting the contact onto the wire.
  • Solder: the process of joining metal items by melting and flowing of the solder.
  • Tin: the process of making hot solder flow over a stranded wire.
  • Heat Shrink: the process of protecting wire with a plastic tube that shrinks when heated.

• Connector Assembly is the process of connecting wire with ribbon cable, coax, and triax connectors (inserting contacts, wire seals, plugs, wedgelocks; attaching backshells, shrink boots, strain reliefs, dust caps, and so forth).

• Splice is the process of joining free ends of wires into the circuit. Ends can’t be disconnected after splicing. Splice includes:

  • Ultrasonic Splice: bonds multiple wires together by applying the energy of high-frequency vibrations.
  • Butt Splice: connects two wires together to lengthen, change, or repair an electrical circuit.
  • Insulation Displacement Splice: inserts wires into a connector and squeezes it together without stripping or twisting wires.

• Harness Layout is the process to create the final harness assembly of all components using harness boards (could include testing of connectors). Harness Layout includes:

  • Formboard setup and testing of connectors.
  • Layout of flexible and stiff wires, cables, etc.
  • Cable tie during branch layout
  • Twisting of wire bundles.

• Branch Covering is the process used to create a protection cover for the harness assembly (tube or sleeve, seal tape, heat shrink, split tubing).

• Braid is the process to create the wire harness assembly composed of threads woven tightly around a wire bundle. Wires are pulled through a machine and the braid is woven securely onto the cable.

• ID Label is the process to put notes or labels on the wire bundle (logos, barcodes, sequential numbers, and so forth) to provide a clear, reliable, and durable way to identify wires and cables.

• Test is the process of checking the wire assembly for compliance with claimed requirements. Tests include:

  • Pull Test – measuring wire bond strength, evaluating the bond strength distribution and determining compliance with specific requirements.
  • Continuity Test – placing a small voltage across the chosen path to detect the presence of a complete path for current flow.
  • HiPot Test – detects the absence of current flow between two points and verifies that insulation is sufficient to protect the operator from electrical shock.