Wire Selection for Harnesses and Cables

Conductors

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When folks think of wire they tend to think of copper, but there are many kinds of wire used in cables and harnesses including:

• copper plated with other metals such as nickel, tin,and silver

• alloys such as beryllium-copper, cadmium bronze, alumel

• fiber optic cable made with either plastic or glass

No matter what the material of the conductor/wire, it is available in a variety of gauges or sizes. Selecting the proper gauge depends on the amount of power and/or data being transmitted and the length of the cable. Since different types of wire have different physical and transmittance properties, selecting the proper gauge is critical. Wire with larger diameters, lower gauges, carry heavier loads and are better suited for larger appliances and industrial applications. Wires with smaller diameters, higher gauges, are best suited for small appliances, delicate medical instruments, etc.

Insulation and Jacketing

Since bare wires are not used in components, virtually all wires have a layer of insulation which is typically either thermoplastic or thermoset plastic. The latter, which is more expensive, is typically used when the wire harness or cable assembly is going to be exposed to high temperatures and must not melt and must remain flexible. The list below shows some common types of plastic used for wire insulation.

• Thermoplastic: PVC (Polyvinyl Chloride), PE (Polyethylene), ECTFE, PVDF, Nylon

• Thermoset: XLPE, CPE, EPR, Neoprene

In addition to insulation, wires may require an additional protective jacket which could be made of a nylon, cotton, glass, Kevlar or metal sheathing. The type of wire insulation and additional jacketing depends on the application and operating conditions the finished wire product will be exposed to. For example, if the cable is for aerospace or industrial use, the cable will require high level of ruggedization to ensure

• Toughness, tear and abrasion resistance

• Flexibility during cable installation, at low temperature

• Stability over a range of temperatures

• Resistance to heat aging

• Resistance to cable deformation

• Low moisture absorption

• Oil resistance

• Resistance to abnormal concentrations of chemicals

• Weather or ultraviolet resistance

Wire Configurations

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In addition to the actual type of wire and its jacket, wire comes in dozens of configurations. Listed below are just a few:

• single strand, aka single conductor

• multi-strand, including duplex, triplex, or quadruplex

• multicore

• ribbon format

Processability

Lastly, how easy is it to process the wire? This simply means how easy/difficult will it be to cut, strip, and add the desired connectors to the wire. While processability may not affect the final product&#;s function, it may affect the price to manufacture the wire harness or cable assembly. For example&#;.if the wire&#;s end usage is in a medical product will it be easy to strip the insulation with a laser wire stripper? If the jacketing is woven, does it fray too easily? Is the insulation&#;s melt point high enough to permit needed welding, potting or other manufacturing operations?

These are just some of the factors that product designers should consider in regards to what we call your product&#;s nervous system-- the design of the wire harness or cable assembly. It is critical that material decisions be not solely on the basis of cost, but on the application and operating environment. Finally, the materials selected should be compatible with the manufacturing process as well.

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A wire harness is a common and effective tool for keeping multiple wires within a piece of equipment in order. On a more basic level, it&#;s the exterior covering, or sleeve, that encases and protects an inner conductor or bundle of conductors. Known for their straightforwardness, effectiveness, and low cost, these simple casings are designed to streamline and organize multi-wire systems while protecting the wires from the elements, resulting in a cleaner, safer working environment.

As small as they are, however, wire harnesses can vary widely. In fact, most companies customize them so that they&#;re better suited to particular environments and applications. We&#;re here to help outline the basics of these essential implements so that you can find the perfect type for your company.

Types of Wire Harnesses

Wire harnesses can be made from a number of durable materials. Some of the most common include:

• PVC
• Vinyl
• Thermoplastic elastomer
• Polyurethane
• Polyethylene

The specific material used in a harness largely depends on its surrounding environment. If the wires are run in a particularly damp environment, for example, the harness should be of a material that effectively resists moisture such as polyethylene.

Regardless of the material with which it&#;s made, wire harnesses can be further specialized to suit particular applications. Additional features often found in wire harnesses include:

• Wire ties
• Lacing
• Insulation materials
• 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

Just as certain materials are better suited to certain environments, certain features of wire harnesses are better suited to certain applications. Any wires at an increased risk of abrasion, for example, should be enclosed in a harness with heat-shrink coating, since heat-shrink coating is designed to minimize the effects of abrasion.

Applications of Wire Harnesses

Wire harnesses are highly versatile products that are well-suited to use in nearly every industry. Aerospace, automobiles, medicine, telecommunications, and commercial construction, as examples, constantly depend on them for smooth operations. Wire harnesses can also be found in home electronics, audio and visual equipment, and household appliances.

At Consolidated Electronic Wire & Cable, we&#;re proud to offer a wide selection of harnesses and cable assemblies that meet even the strictest standards. We can specialize in personalized solutions to common industrial challenges, offering all customers specialized shielding, fillers, materials, identification, and style. Our harnesses can accommodate systems up to 600 volts (UL) or volts (military) and can withstand temperatures ranging from -65 °C (-85 °F) to 250 °C (482 °F), ensuring functionality in any environment.

For over a century, Consolidated Wire has set the standard in industrial wiring and cabling, helping companies of every size develop lasting solutions to and select the right wires for all of their electrical challenges. To learn more about our extensive wire and cable harness offerings and explore their benefits, check out our catalog today.

Contact us to discuss your requirements of Harnesses Wire. Our experienced sales team can help you identify the options that best suit your needs.