WIRING HARNESS

Submitted By: Ashish Kumar Sharma 2009Btec002

WHAT IS WIRING HARNESS?

A cable harness, also known as a wire harness, cable assembly, wiring assembly or wiring loom, is an assembly of cables or wires which transmit signals or electrical power. The cables are bound together by straps, cable ties, cable lacing, sleeves, electrical tape, conduit, a weave of extruded string, or a combination thereof.

COMPONENTS OF WIRING HARNESS

Wires Terminals Connectors Caps & Sleeves Fuse Boxes

WIRES

Wire is a single, usually cylindrical, flexible strand or rod of metal. Wires are used to bear mechanical loads and to carry electricity and telecommunication signals.

LABELS & SYMBOLS: AUTOMOBILE WIRING DIAGRAM

Color CodesB - Black color wireBR - Brown color wireDRK GRN - Dark green color wireG - Green color wireL - Blue color wireLG - Light green color wireO - Orange color wireP - Pink color wireR - Red color wireSB - Sky blue color wireV - Violet color wireW - White color wireY - Yellow color wire

TERMINALS

Push On Terminal

Copper Terminal

Correct way to put terminal on wires

CONNECTORS

Connectors are used to make connectionsFrom one device to another

CAPS & SLEEVES

Caps are used to protect the terminals from being damaged.

Sleeves are used to protect the wires from shrinking due to high currents.

FUSE BOX

To protect the wire lines from short when high Intensity of current is passed.

MANUFACTURING PROCESS

STEP 1 Terminals are fixed on wires Then with the help of applicators wires are cut on CNC machine

C n c machine

MANUFACTURING PROCESS(CONTD…)

STEP 2 Quality of the wire is being checked by

the Quality Analyst Parameters to be checked; PVC of the wire Terminals of the wire Width of the terminal

MANUFACTURING PROCESS(CONTD…)

STEP 3

Taping is done on thewires to protect them from moisture and heat

MANUFACTURING PROCESS(CONTD…) After taping, quality is checked Then packing is done And the final products are dispatched

to the market.

SAFETY MEASURES (DO’S)

Always keep the area around the machine clear of obstacles.

Always put material where you can reach it. Always check that tools are sharp and set correctly. Always check that the correct tool data is entered

into the CNC program Always make sure that all guards are in position

while the machine is in operation. Always follow company policy on correct procedures

when handling or lifting parts or tooling.

SAFETY MEASURES

 DON'T: Do not use the machine table as a

workbench. Do not use compressed air to blow

chips from the parts of the machine, machine surfaces, cabinets, controls or floor around the machine.

ADVANTAGES

Advantages over loose wires and cables

Adverse effects of vibrations, abrasions, and moisture.

Usage of space is optimized Risk of a short is decreased Installation time is decreased and the

process can be easily standardized

Thank You