Before designing your wire harness, you need to follow the standard guidelines and best practices which you can also learn in more detail when you take an IPC 620 certification online with training.
In addition to acquiring an IPC certification online, you’ll also be able to avoid costly mistakes in your design by considering the multiple factors below:
1. Environmental Conditions
The first thing you must consider in your wire harness design among several factors is to determine the physical environmental conditions where your harness is going to be exposed.
Example of these conditions are as follows
· Extreme temperatures (hot or cold) Like wires to be routed near an engine or exhaust
· Areas with moisture/water, dirt/debris, oil, or chemicals.
· Areas which exposes wires to scraping, or shock/vibration
With these conditions in mind, you need to select the right kind of cable harness that will ensure protection from failures and insulation breakdowns.
2. Dimensions And Tolerances
You also need to be clear on your required lengths, and tolerances for the wires. They should be long enough for bend radius and must reach the connector.
Another thing you might want to consider measuring is the wire ends, including the strip lengths.
3. Covering
Different types of coverings have their distinct purposes, and their own advantages and disadvantages. As a wire harness designer, it’s your job to identify which cover suits a specific application.
And you should also take note that not all parts of the wiring will require covering because sometimes, it causes a disadvantage with flexibility and future troubleshooting.
Examples of different covering types are braided loom, woven, split sleeve, tape, or conduit.
4. Wire Coloring And Labeling
If you require labels to help you quickly identify circuit names, you need to note on your drawing your prefered wire colors, and the text you want to be printed, or labelled on the wires.
Note the following: color, text, connector labels, wire labels, or assembly label.
5. Wire Type
The type of wire you choose should also be based off its application because different wire types each have their own uses.
Different wire types have different voltage ratings, insulation material, and plating (bare or copper). GXL and TXL wiring are best used for automotive purposes, while UL1015, UL1032, and UL1230 are best suited to control panels.
6. Splicing And Splice Locations
The method of splicing a wire also have different variations categorized by their specific use. Carefully review this factor before designing your harness.
Examples of splicing methods are as follows: mechanical crimps, ultrasonic welds, jumps/daisy chain.
7. Testing
The last most important step is to identify the testing method. Various testing types are as follows
· Continuity test
· High voltage test
· Functionality testing
· Cycle testing
Determine the type of testing based on specific use/application.
8. Conclusion
The wire harness effectivity, and functionality, will heavily depend on the design quality - an aspect of electronics assembly which is heavily emphasized when you take an IPC certification online. A good design ensures that malfunction doesn’t occur, improves the service life of the wires, and organizes wires for easy access, maintenance, and troubleshooting.
All wire harness designs must adhere to IPC/WHMA-A-620, so that’s the best place to start. Consider acquiring an IPC 620 certification online to help you develop the right wire harness solution for your specific needs.
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