Understanding the Intricacies of Cable Harnesses

Cable harnesses are used in almost every industry pretty much every day. These simple designs hold and organise multi-wire systems, improving productivity and safety, among many other things. From transport to aerospace you will find cable harnesses everywhere today. In the home, in the office, across institutions and organisations, they have a vital role to play. This is what you need to know about cable harnesses to be able to understand them.

How do cable harnesses work?

The cable harness is the exterior cover that is applied to an inner conductor or bundle of conductors. The harness can provide vital protection to the conductors inside, as well as organisation and safety. Cable harnesses are able to be highly effective, even in harsh environments and high pressure situations – but they are also very simply designed and cost effective. Custom cable harnesses are those that have been intentionally designed with a particular specification in mind. That may be to accommodate a certain voltage, temperature or set of environmental conditions, for example. Custom cable harnesses can have a range of different features, including heat-shrink coatings, custom colours, individual tagging and custom insulation and shielding.

What factors influence the design of cable harnesses?

• The conditions that the cable harness will need to operate in e.g. indoors or out.
• The amount of flexion required.
• The number of circuits and conductors that will be in the assembly.
• How much voltage needs to be carried.
• Exposure to anything harmful, such as toxic chemicals or sunlight.
• The range of operating temperatures.

Where are cable harnesses usually found?

There are cable harnesses being used in industries all over the world – these are just a few examples:

• Automotive to ensure lighting and signals work, as well as organising the wiring that is under the hood.
• Aerospace, for example in drones and satellites, as well as aircraft to facilitate the transition of power, communication etc.
• The medical sector to protect and organise the wires that are used in the wide range of equipment required for hospitals and research.
• To enable telecommunications, for example in routers and modems and a range of other internet delivery equipment.
• Construction to help with wiring insulation and organisation.
• In manufacturing, where CNC machines and other equipment are reliant on cable harnesses.
• Robotics and automation to help ensure grouping and safety of vital wires and cables.

What are the benefits of cable harnesses?

• Much more cost effective than individual assemblies.
• Vital for organisation, especially where there are thousands of metres of cables.
• Help to make installation and repair more efficient.
• Provide protection from the elements outdoors and from things like moisture indoors.
• Create a safer working environment, as there are no loose wires or cables that could be damaged or do damage.
• Improve safety because there is less of a risk or short or fire.

Cable harnesses are a key part of dealing with wires and cables for any industry today. They are cost effective, improve productivity and help to ensure conductor longevity too. At GEM Cable we are AS9100D & BS EN ISO 9001:2015 and ISO 14001-2015 certified UK manufacturers of bespoke cable assemblies, control boxes, harnesses, wiring looms, panels, fibre optic products and total network solutions.