Every Possible Issue Related To Wire Harness – The Problems & Solutions – Miracle Electronics

Wire harnesses are engineered for different applications, but they play a critical role mainly in electrical and electronic devices and systems. Their rugged construction helps them to withstand almost all kinds of impacts and environments such as extreme temperature, humidity, compression, friction, vibration, etc.

 However, these harnesses can experience certain issues that can stop them from working as expected. Below, we’ve highlighted some of the most common problems that occur, along with some ways to either avoid the issues or resolve them.

Common issues

While there could be multiple kinds of problems seen within a wire harness, the most common issues include –

•         Poor performance
•         Shorter lifespan
•         Incorrectly placed components
•         Missing components or wires
•         Oxidation
•         Corrosion
•        Circuit issues

The causes

Inappropriate material selection – If the material chosen to build the harness is not one that can withstand the environmental forces in which it is to be installed, it can lead to poor quality and deteriorated performance.

Incorrect wire preparation – Not only is selecting the material important; it’s also vital that the wire is cut tothe right length, stripped right , and connected correctly. Failing to do so can lead to incorrectly prepared components.

Incorrect installation – Any imperfections in installing the wires can result in imbalanced pressure, circuit issues, and deterioration in the quality and performance over time.

Inadequate/flawed testing – If the harnesses are not tested properly, it may lead to missed issues that may cause bigger problems in the future.

Incomplete protection – Oxidation and corrosion are quite common to occur when certain metals come in contact with air and moisture.

The solution

It is very important to test the harnesses in order to eliminate all the above issues. Testing them after completion of every manufacturing stage, as well as after completion of the entire process, is essential. This brings forward any issues immediately so that the problem can be resolved at the earliest before moving on to the next stage. This results in reduced wastage of time, material, and labour. There are five different ways in which the harnesses can be tested.

Visual testing – This involves visually analyzing if every component is placed correctly or not; for instance, the dimensions, the gauge, the placement, the connectors/terminals , and the labelling.

Mechanical testing – This involves testing the mechanical properties such as flexibility, tensile strength, elongation, impact resistance, and crush resistance.

Electrical testing – This involves assessing the electrical performance; whether or not the configuration and performance are proper or not. Open wires, incorrect wiring, and shorts are tested for, by connecting the harness to an electrical fixture.

Environmental testing – This involves testing whether the harness can withstand the environmental conditions it is installed in, such as humidity, temperature, pressure, and vibration.

Signal integrity testing – This involves assessing the strength of the signals that can be carried, which include signal error and crosstalk. Whether or not the signal strength can be maintained with the integration of connectors, filters, or splices is also checked for.

Partnering with Miracle Electronics

You can see how it is important that you partner with a professional wire harness manufacturer like Miracle Electronics, where the harnesses are not only manufactured, but also tested at every stage to identify for potential errors at the earliest, so as to reduce wastage of time and labour, and bring to the client a thoroughly tested end product.

 

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Why Should You Hire The Services Of Contract Electronics Manufacturers?

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How Have Power Transformers Proved To Be A Boon For Today’s Industries?

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How Do Power Transformers Fight Power Fluctuation?

We all are so highly dependent upon machines for everything today. While earlier, machines were seen to be used mainly in commercial applications where the same tasks were very difficult or impossible to be executed manually, today machines are used in every small task. We have become so dependent that we see luxuries in owning machines like air conditioners, televisions, refrigerators, and washing machines. But, do you know that all these appliances cannot work until and unless safe amounts of electricity is supplied to them? This means that all these appliances are of no use without transformers aiding in stepping up and down the voltages as required of the power supply that comes from the power stations into these appliances.

Why Are Electrical Wires Mostly Round In Shape?

Electrical wires transfer electricity from one point to another; and to carry out this function effectively, these wires are made up of an insulator, a conductor, and a protective sheath. The insulator present protects the wire from electric shock; the conductor provides the medium for flow of electricity; and the sheath protects both the insulator and conductor from outer damage.

How Do Transformers Help In Transmitting Electricity To End Users

Have you ever wondered how electricity is brought into our homes and offices? You know that it is superbly huge amount of power generated at the power stations, right? And, you also know that this huge supply if brought into your homes can cause serious damage to your appliances and death too. So then, how does this huge power get into your homes so safely? It is through a power system comprising of various step up and step down transformers. Step up transformers increase the voltage, while step down transformers decrease the voltage.

How To Identify Professional Cable Harness Manufacturers

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Why Is Customizing Wire Assemblies Important?

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Choosing The Right Cable Harness Manufacturer

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All You Need To Know While Purchasing An Automotive Wiring Harness

Automobile wiring harness is an assembly of electrical wires, connectors, and other electrical components mounted in automobiles for transmission of power and energy. It has good pliability and great capacity to resist high temperature. These wiring harnesses are in huge demand by automobile set-ups because they are ductile in nature, are dimensionally accurate, easy-to-use and have a short assembly time. They provide great safety against the effects of vibrations, abrasions and moisture, and optimize the usage of space as compared to loose wires and cables. The non-flexing bundle decreases the risk of a short and electrical fire by constricting all the wires together.

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How are wiring harnesses helpful in the automotive industry?

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What checks are needed to be made while purchasing a wire harness?

Automobiles require different types of cable harnesses to keep them running smoothly and efficiently. There are a wide range of automotive wiring harnesses available for different range of vehicles like cars, three-wheelers, two-wheelers, utility vehicles and commercial vehicles like trucks and buses. Today, many manufacturers use the finest quality materials to build up these harnesses by strictly examining every stage of production to guarantee the best quality products that bring high safety along with them.

The automobile industry has defined specific standards for wiring harness manufacturers to follow. It is important that you use those harnesses that are manufactured keeping these set standards in mind. So, before you purchase an automotive wiring harness, make sure that it conforms to the industry standards to ensure safety. You can also get customized wiring harnesses as per your requirement like different specifications, colour coding, etc. Check with your engineering department to see what kind of harness is needed for your industry before taking a decision. If you are dealing with Miracle Electronics, you can rest assured that they use only those materials that are of the finest quality, thus making them a leading wire harness manufacturer in India that takes care of every aspect of quality, cost effectiveness and latest technology.