Wiring harness

1. Wiring Harness Submitted By: Ashish Kumar Sharma 2009Btec002

2. 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.

3. Components of wiring harness Wires Terminals Connectors Caps & Sleeves Fuse Boxes

4. 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.

5. Labels & Symbols: automobile wiring diagram Color Codes B  - Black color wire BR  - Brown color wire DRK GRN  - Dark green color wire G  - Green color wire L  - Blue color wire LG  - Light green color wire O  - Orange color wire P  - Pink color wire R  - Red color wire SB  - Sky blue color wire V  - Violet color wire W  - White color wire Y  - Yellow color wire

6. terminals Push On Terminal Copper Terminal Correct way to put terminal on wires

7. connectors Connectors are used to make connections From one device to another

8. 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.

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

10. 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

11. 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

12. Manufacturing Process( contd …) STEP 3 Taping is done on the wires to protect them from moisture and heat

13. Manufacturing Process( contd …) After taping, quality is checked Then packing is done And the final products are dispatched to the market.

14. 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.

15. 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.

16. 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

17. Thank You