Wiring Harness

Wholesale Wiring Harness Manufacturer

Goowell Electrical Co., Ltd is a leading manufacturer of connecting cables, mobile phone data cables, and Apple MFi-certified USB data cables. Our products include iPhone MFi Data Cable, Data Cable, Radio Control, Models Connecting Wire, Wiring Harness, Connecting Cable, UL Wire, Connector.

Why Choose Us

Wide Range of Applications
The company’s products are suitable for all types of electrical devices, including home appliances, medical equipment, new energy vehicles, and 3C-type digital products.

Advanced Equipment
The company has invested in state-of-the-art production equipment, including automatic terminal machines, soldering machines, and injection machines. The automatic terminal machines used by Goowell Electrical are designed for high-speed and efficient production of cables and wiring harnesses.

High Productivity
With its 8 production lines, around 200 workers, and a 20-person R&D team, the company is well-equipped to meet the demands of its customers and provide them with the latest and most advanced products on the market.

Leading Service
The company’s commitment to customer satisfaction is reflected in its comprehensive range of services, including 7/24 support before order, 100% inspection during production, and quality assurance for 1 year.

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Definition of Wiring Harness

A wire harness, often referred to as a cable harness or wiring assembly, is a systematic and integrated arrangement of cables within an insulated material. The purpose of the assembly is to transmit signal or electrical power. Cables are bound together with straps, cable ties, cable lacing, sleeves, electrical tape, conduit, or a combination thereof. The wire harness simplifies the connection to larger components by integrating the wiring into a single unit for “drop-in” installation.

What are Advantages of Wiring Harness？

High-frequency Surgical Knife Wire Harness

Customized Medical Imaging Equipment Cable Harnesses

New Energy High-Voltage Energy Storage Wire Harness

They Save a Lot of Time
One of the major benefits of wires harnesses is the way they can be used to simplify manufacturing processes. No matter what the industry, where cables and wires are required, using wire harnesses can considerably cut down the time involved. Even where many miles of cable are being installed, the use of wire harnesses which can simply be pre-assembled and then dropped in where required – makes everything simpler and reduces the manufacturing time necessary for each item.

Raising Safety Standards
Wire harnesses may have many different functions within an individual design but they will all ensure that the wires and cables involved are kept in place and remain secure. This means they are less likely to be affected by factors such as vibration, moisture or abrasion. When the wires are bundled in a flame retardant material this can also considerably reduce the risk of an electrical fire.

Bespoke and Effective
Wire harnesses are designed for a specific situation using the geometric and electrical requirements of the equipment they are going to be installed in. This can have many benefits, including helping to optimise space inside equipment and avoid previous issues, such as reducing the potential for an electrical short, as wires are in a non-flexing bundle.

Testing and Quality Control
Wire harnesses go through a rigorous testing process that is designed to ensure electrical functionality thanks to a pre-programmed test board. The end product is only sent out to customers once it has been 100% approved and passed by quality control.

Safety
Harnesses can incorporate structural supports, insulation, and shielding to protect against dangerous shorts. Harnesses also keep wires contained to avoid accidents in the workplace.

What are Features of Wiring Harness?

Individually insulated wires

Used to keep electrical systems organized

Ideal for spatial constraints

Simplify installation

Custom Wire Harnesses

Wire ties.
Lacing.
Insulation materials of all kinds.
Custom colors.
Heat-shrink coatings.
Custom labeling or barcoding.
Four-color ink stamping.
Individual tagging.
Independent circuit IDs.
Polypropylene, nylon, and paper fillers.
Custom shielding.

Differences Between a Wire Harness and a Cable Assembly

Environments

Each is utilized in various environments. Wire harnesses provide minimal protection for wires. Its purpose is to organize wires and cables efficiently. It cannot shield them from extreme temperatures or friction between one another. They are fundamentally used for indoor use. Cable assemblies guard all the products safe in the most extreme conditions and are ideal for outdoor use. It’s a high-level resistance to outside variables such as heat, dust, and moisture. It also protects the wire and cables from friction and corrosion.

Cost

Wire harnesses are a low-cost electrical solution that best keeps electric cables and wires organized. By bundling these wires and cables together, engineers can keep their wiring systems organized. It doesn’t concentrate on giving added protection to its wires and cables and usually requires less material and effort. Thus, it costs less compared to the cable assembly. Although cost-friendly, it still relies on the type, number, and quality of cables, wires, or connectors used in the production. However, the cost of the cable assembly is satisfactory because of the added protection it provides. Cable assemblies offer more vigorous protection by keeping components snug within a rugged outer sheath. In addition, cable assemblies are intended to be utilized in demanding environments where things like heat, friction, or moisture could untimely wear out a cable or wire.

Physical Attributes

The essential difference between a wire harness and a cable assembly is their physical attributes and function. A wire harness offers a cover that encases single cables, usually from the same material utilized in a cable assembly. One can see and remove an individual cable from a wire harness. In comparison, a cable assembly has multiple wires but is bundled together by a single external sleeve. It comes as a only one thick wire.

Products

Many of our everyday household products and tools use wire harnesses. These products are computers, televisions, monitors, microwaves, and refrigerators. These products use wire harnesses rather than of cable assemblies because these products come with a protective shell, which removes the requirement for added protection. Wire harnesses are also present in most automobiles and airplanes.

Cable assemblies are used for severe environmental conditions or extreme temperature changes. In addition, many heavy industries such as medical, military, aerospace, and construction generally use cable assemblies in their manufacturing processes. They need the cable assembly to protect areas such as the electric flow in its wires or cables. They are the perfect for high-speed data transfers.

Purposes

Wire harnesses serve two primary purposes:

To protect outside factors from harm caused by the flow of electricity.

To ensure wiring systems are organized and straightforward for technicians to understand.

Cable assemblies serve three primary purposes:

To protect outside factors from harm caused by the flow of electricity.

To ensure wiring systems are organized and straightforward for technicians to understand.

To protect the wiring or cable against wear and tear or other harsh environmental conditions.

Applications of Wiring Harness

Aerospace: Wire assemblies are used in an expansive range of aerospace products, such as drones, satellites, and aircraft to facilitate the transmission of power, communication, and more.

Automotive: Wire harnesses are critical for saving valuable space within automobiles within the dashboard, under the hood, lighting/signals, and more. They are also important for organizing complex wiring in such a way that technicians can easily identify their purpose.

Medical: Hospitals and clinics rely on wire harnesses to organize and protect wires in and between equipment, including crash carts, diagnostic and imaging equipment, dental equipment and more.

Telecommunications: Wire harnesses optimize use of space in a variety of telecommunications equipment, such as modems, routers, repeaters, and a variety of other communication and broadband equipment.

Information Technology: Nearly all computers, laptops, servers, and other IT technology contain wire harnesses to optimize space and organize wires for easy identification and installation by technicians.

Construction: Wire harnesses are widely used within structures to provide wiring insulation and organization.

Manufacturing: CNC machines and other powered manufacturing equipment rely on wire harnesses to route and organize external and internal wiring.

Robotics and Automation: Wire harnesses are used on most automated equipment and robotics to safely route, group, and protect critical wiring.

Process of Wiring Harness

A wire cutting machine cuts the wires to the desired length.

Both ends of the wires are peeled to expose the metal of the wires.

The ends are covered with the required terminals or connector housings.

According to the design specifications, the wires are assembled and clamped together on a pin assembly board to form the cable harness.

New Energy Storage Power Wiring Harnesses

The Considerations for Buying

Whether the harness will be exposed to continuous flexion.
If the harness will be used indoors or outdoors, and under what specific conditions.
How many circuits and conductors are required for the assembly, as well as their characteristics.
Level of voltage to be carried.
Potential exposures, including chemicals, corrosive fluids, weather conditions, and moisture from other sources.
Maximum, minimum, and average operating temperatures, as well as possible fluctuations.
Local safety and environmental regulations that might impact the component selection, installation, and inspection.
Routing, breakouts, the general shape of form.
The shape of the electronic device.
Bending points.

Our Factory

The large workforce at Goowell Electrical allows the company to efficiently manage its production processes and meet customer demands. The experienced workers are trained to use the latest technology and equipment to produce high-quality products that meet the strictest standards for quality and reliability.

Our Service

The company’s 7/24 support before ordering ensures that customers receive the information and assistance they need to make informed purchasing decisions.

Whether you have questions about product specifications or need help with an order, Goowell Electrical’s customer service team is available to provide support and answer any questions you may have.

The company’s 100% inspection during production ensures that each and every product is thoroughly tested and inspected before it is shipped to customers.

Goowell Electrical also provides quality assurance for 1 year, giving customers the peace of mind that comes from knowing that their products are backed by a commitment to quality and reliability.

Our Certificate

The company has obtained a number of certifications that demonstrate its commitment to excellence, including ISO 9001, Apple MFi, High-Tech Enterprise, UL/CE/FCC/ROHS, and others.

Contact Us

write to us

Email: gwkathy@shusb.com

visiting us

Address: 5th floor, Building 1, Shajing Industrial Park, Haoxiang Road, Shajing, Baoan District, Shenzhen

Contact directly

Tel: +86-755-27086770

Mob: +8613826575395

Frequently Asked Questions

Q: Why Are Wire Harnesses Assembled Manually?

A: Wire harness assembly process is one of the few remaining manufacturing processes that is more efficiently done by hand, rather than automation. This is due to the variety of processes that are involved in the assembly. These manual processes include:

Installing terminated wires in various lengths

Routing wires and cables through sleeves and conduits

Taping breakouts

Conducting multiple crimps

Binding the components with tape, clamps or cable ties

Because of the difficulty involved in automating these processes, manual production continues to be more cost-effective, especially with small batch sizes. This is also why harness production takes longer than other types of cable assemblies. Production can take anywhere from a few days to several weeks. The more complicated the design, the longer production time is required.

However, there are certain portions of pre-production that can benefit from automation. These include:

Using an automated machine to cut and strip the ends of individual wires

Crimping terminals on one or both sides of the wire

Plugging wires pre-fitted with terminals into connector housings

Soldering wire ends

Twisting wires.

Q: What is the process of Wiring Harness?

A: A wire harness process is designed based on the geometric and electrical requirements of the equipment it is to be installed in. Once the initial design is established, a schematic is used to create the manufacturing paperwork and the assembly board for the harness. The assembly board, also called a pin board, is a full-size diagram of the harness which shows all of the components and their locations. It also serves as the workbench for the harness.

The wires needed for the harness are first cut to the desired length and labeled appropriately. Next, the ends of the wires are stripped to expose the uninsulated conductor and fitted with any required terminals or connector housings. The wires and components are then assembled on the pin-board to the desired specification and then bound together.

Q: What are the factors affecting Wiring Harness?

A: Whether the harness will be exposed to continuous flexion.

If the harness will be used indoors or outdoors, and under what specific conditions.

How many circuits and conductors are required for the assembly, as well as their characteristics.

Level of voltage to be carried.

Potential exposures, including chemicals, corrosive fluids, weather conditions, and moisture from other sources.

Maximum, minimum, and average operating temperatures, as well as potential fluctuations.

Local safety and environmental regulations that might impact.

Component selection, installation, and inspection.

Routing, breakouts, general shape of form.

Q: What are the advantages of Wiring Harness?

A: Wire harnesses would not be so widely used if they didn’t present substantial benefits for wiring applications. Among other advantages, wiring harnesses benefit companies in the following ways:

Decreases cost compared to multiple individual assemblies.

Improves organization, especially when a system relies on hundreds of feet of complicated wiring.

Decreases installation time for projects involving extensive networks of wiring or cabling.

Protects conductors from the elements outdoors or from chemical and moisture exposure indoors.

Provides a safer work environment by cleaning up loose or scattered wires, maximizing space, and preventing trips and damage to wires and cable.

Enhances safety by minimizing the risk of shorts or electrical fires

Decreases installation and maintenance time by potentially minimizing the number of connections and organizing components in a logical configuration.

The many benefits of wire harnesses stem from very simple design principles. Sheathes protect wires against abrasion or exposure to hazards, minimizing the risk of workplace incidents. Connectors, clips, lacing, and other organizational strategies drastically reduce the amount of space that wiring must occupy and ensure that technicians can easily locate the components that they need. For equipment or vehicles that regularly contend with a web of lengthy wires, a wire harness is sure to benefit everyone.

Q: What are the insulation materials for Wiring Harness?

A: In addition to ensuring optimal organization, a high-quality wire and cable harness will provide reliable insulation and protection for the conductors within. There are many options for durable harness materials, and it’s important to select what is most beneficial for your needs.

Some of the most common insulator materials include:

PVC, or polyvinyl chloride

SR-PVC, or semi-rigid polyvinyl chloride

Cellular polyethylene

EPDM, or ethylene propylene diene monomer

TPE/TPR, thermoplastic elastomers

PE, or polyethylene

Both low- and high-density polyethylene (LPDE and HDPE)

Cellular, or foam, polyethylene

PU, or polyurethane, as well as polyurethane and nylon blends

Low-smoke plenum copolymers

Polypropylene (PP) and cellular (foam) polypropylene

FEP, or fluorinated ethylene propylene

TFE, or tetrafluoroethylene

PTFE, or polytetrafluoroethylene

ETFE Tefzel

PVDF Kynar

ECTFE Halar

IRR/PVC, or irradiated polyvinyl chloride

XLPE, or cross-linked polyethylene

Vinyl

In choosing between these and other options, it’s important to take into account environmental variables such as operating temperature and moisture. The presence of moisture, for instance, can necessitate a water-resistant material like polyethylene to avoid damage to the conductors.

Q: Why are Wire Harnesses Important?

A: A wiring harness is crucial for the protection of your electronics. Some of the main functions they serve include:

Helping to increase the lifespan of your electronic device by protecting it from compromised wires and heat damage.

It serves as a backbone when connecting digital components to each other or to other components.

Improving airflow within the chassis.

Protecting technicians from electric shock.

Providing a more organized work environment.

Reducing damage to your electronics from dust and debris.

Q: What is the Value of a Custom or Quality Wire Harness?

A: The value of wiring harness varies as they are used in a number of applications. Because of this, the harness is not a one-size-fits all proposition. Instead, the wire harness should be customized according to the size of the space that the wires are going to fit into, also taking into consideration the weight of the wires themselves. Although wire harnesses are designed to be a low-cost solution to providing organization for technicians and protection for technicians and equipment, they also should be high quality to ensure the most impact.

Q: What is wire harness engineering?

A: A wire harness is a system of insulated conducting wires bound together with insulating materials, used in the electrical system of a motor vehicle, complex machine or aircraft. Wire harness engineering is the development process of an electrical foundation for the safe and reliable distribution of power throughout a system. It forms the foundation of reliable, cost-effective and successful product design and manufacturing.

The design, engineering and manufacture of wiring harnesses is complicated by shorter program launch cycles and increasing price pressure, coupled with increasing product and configuration complexity. Harness design software helps many companies address wire harness engineering challenges. Powerful design automation capabilities, coupled with model-based wiring harness engineering flow, help harness manufacturers cut costs, improve product quality and boost efficiency.

Q: What is the purpose of a wire 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. For example, in some modern vehicles there are approximately 40 different harnesses, comprised of roughly 700 connectors and more than 3000 wires. The bundling of wires and cables into a wire harness simplifies connection to larger components as a single unit for drop-in installation, instead of connecting every individual strand.

Q: What is wire harness design?

A: Wire harness design is the process by which an engineer evaluates the requirements of an electrical part of system, given available physical space to create an assembly of wires to deliver power and information as needed. The design must connect all necessary components and not interfere with other systems critical to the operation and purpose of the product.

For example, a wire harness in an airplane must power everything from flight controls to passenger comforts and landing gear. The wire harness design must consider and account for mechanical systems, passenger and crew comfort, weight distribution, plumbing and more to ensure safe and efficient transport.

Q: Why are wire harness & cable assembly often confused?

A: By nature, both wire harnesses and cable assemblies contain cables and wires. The main difference is in the engineering of the component to match the application. Wire harnesses are low-cost means with which to provide a bundle of cables and wires some degree of protection, while keeping them organized for ease of installation and future service. Cable assemblies provide a much more robust protection by keeping components snug within a rugged outer sheath. Cable assemblies are meant to be used in demanding environments where things like heat, friction, or moisture could prematurely wear out a cable or wire.

Q: What is the difference between a wire and a cable?

A: The core of the differentiation between wire harnesses and cable assemblies lies in the fact that wires and cables are two entirely separate things. A wire is a single strand of a conductive material like tin or copper. Once a bundle of wires are twisted or braided together and contained within a protective outer sheath, they have become a cable.

Q: How are wire harnesses made?

A: Wire harnesses go through many stages of design and manufacturing before a concept is ready for in-field use. First, our brilliant design team will meet with the client to determine the specs of the project. The design team use tools like computer aided drafting programs to produce the measurements for the necessary components of the system.

Once design elements are finalized, we move on to prototyping. Prototyping allows us to produce multiple iterations of the proposed design. Prototyping also affords our design staff the time to see if different source materials will be viable logistically. If a certain elements don’t arrive in an efficient and economically viable manner, it can throw off the whole manufacturing process and increase expenses. Prototyping allows for any logistical hurdles to be worked out ahead of production runs so the process can proceed as smoothly as possible. The prototype iteration will also help our production team know which tools will need to be reserved from our custom tool crib.

Once all of these elements have been smoothed out, the unit will progress into volume production, final testing, and ultimately, distribution to their intended destinations.

Q: How can wire harnesses offer a low-cost solution for keeping wires organized?

A: Wire harnesses can help group together specific sets of wires and cables within a system that are intended to serve a different purpose. Within an industrial control system like those that automate a manufacturing process, a multitude of different cables and wires will generate the necessary signals, data, and power that runs the system’s many moving parts. Because they are not made to have to withstand the same external pressures as a cable assembly, a wiring harness helps engineers and contractors to cost-effectively keep everything efficient and organized within the space.

Q: In what fields can Wiring Harness be used?

A: Aerospace

Aerospace equipment often includes dense bundles of electrical and communication cables. Wire harnesses enable power transmission in aircraft engines, data transmission from satellites, and similar aerospace applications.

Automotive

The automotive industry makes extensive use of wiring harnesses and cable assemblies, including in both gasoline and electrical vehicles. In these contexts, harnesses are indispensable for saving space and ensuring wires fit around mechanical components. Organizing conductors is also essential for keeping distinct systems separate under the hood, enabling both efficient operation and easy maintenance. Automotive systems using harnesses include lights, turn signals, displays, and more.

Medical

In the hospital, clinicians must be able to quickly establish reliable connections. In many cases, this is a matter of life and death, such as when setting up critical care equipment. Harnesses enable these rapid links, keeping patients safe. Other medical applications include more permanent installations such as imaging equipment and dental chairs.

Telecommunications

Telecommunications systems may include anywhere from tens to thousands of cables, all of which must be organized to save space and facilitate identification. Assemblies serve this role, bundling cables for modems, routers, and similar communication equipment.

Information Technology

Within IT, harnesses are used at every scale. Wire harnesses and cable assemblies save space within small laptops and organize the thousands of cables within a networking facility.

Construction

Safe and efficient wiring powers residential and commercial buildings alike. Construction personnel rely on harnesses to insulate and organize electrical wiring in compliance with all relevant codes.

Manufacturing

In a manufacturing environment, stray wires represent a significant safety hazard. At the same time, many machines include extensive wiring, including CNC units, 3D printers, and conventional workstations. Harnesses keep facilities safe by containing wiring and ensuring connections are reliable.

Robotics and Automation

Robots of all sizes require organized and durable wiring to function properly. Often, space is limited, so harnesses are needed to route and contain circuits.

Q: What are the advantages of Wiring Harness?

A: Price & Cost Effective Solution

The price of the high-quality line harness products is in a reasonable and affordable position. The wire harness system makes the intricate wiring very simple. Moreover, the troubleshooting of the problem becomes easy with the use of it. The wire harness can be easily replaced with a new one after simply removing it from both end connectors.

Quality & Durability

The wire harness system is innately very strong, and there are almost no chances of its failure. As a result, the robustness of the harness makes it suitable for all types of printed circuit boards used in electronics circuitry.

The single wire may damage with an impact force on it. However, the system becomes more reliable when we use a bunch of wires in the flat wire harness.

Technology Mature Operation

The wire harness is manufactured on a computerized machine and there is no chance of defect. Also, automatic testing is done to ensure the healthiness of the harness. Overall, we can say it takes very little time to manufacture wire harnesses on the machine rather than soldering individual wire on the circuit board.

Decreased Installation Time

Equipment requires miles of wiring for its operation. If we connect the individual wire, how much time will it take? Further, the chances of human error are always there. The wire harness system simplifies the manufacturing of vehicles and electronic cards. Installation becomes very simple because we need to only drop in the harness, rather than run all the wires individually.

Security & Safety

When we bound the wires and cables with a single harness, it enhances the security of the system because of the following reasons.

Protection against the adverse effect of vibration.

Secure the system against abrasion.

Hinders moisture ingress.

Space optimally utilized.

We're well-known as one of the leading wiring harness manufacturers in China. If you're going to buy or wholesale high quality wiring harness for sale, welcome to get quotation and free sample from our factory. Also, customized service is available.

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