wire and cable harness assembly
wire and cable harness assembly

Cable & Wire Harness Assembly Services

Harness assembly, as a fundamental component in complex electronic systems, is the process of assembling electrical wires and cables into a single bundle. This process enables seamless power and signal transmission within various devices and machinery, ensuring the efficient and reliable operation of electronic equipment across various industries.

The complexity of harnesses can vary depending on the application. A simple harness may contain only a few wires, while a complex one may consist of several hundred or even thousands of wires. The complexity of harnesses varies based on the required functions and connectivity needs, meeting the specific requirements of different electronic systems. Furthermore, they can be shielded or unshielded, with shielded harnesses used to protect wires from electromagnetic interference (EMI), which is crucial for maintaining signal quality.

wire harness assembly

Why FS Technology Harness Assembly Services

FS Technology is a leading PCBA manufacturer headquartered in Shenzhen, providing a wide range of value-added services to global customers, including wire and cable harness assembly. Our team comprises professional engineers and skilled assemblers capable of handling assembly work ranging from single-core to multi-core cables, whether it’s simple wire and cable components or complex custom cables and harnesses.

  • Soluções personalizadas: We offer comprehensive turnkey services, covering Serviços de montagem de PCB, Box Build Assembly Services, and Cable and Wire Assembly, allowing you to tailor solutions to perfectly fit your project’s needs.
  • High Compatibility: Throughout the production process, we conduct thorough checks on product performance, dimensions, and aesthetics to ensure full compliance with design specifications, identifying and addressing any compatibility issues.
  • Cost-Effective: Through efficient labor and raw material procurement, we provide competitive pricing. Additionally, our engineering team actively engages in design projects, offering professional insights to ensure cost-effectiveness without compromising quality.
  • Expertise: Our expertise spans ribbon cables, coaxial cables, and electromechanical components. To ensure production accuracy, we actively validate data and implement revision control to ensure reliable and consistent results.
  • Quick Turnaround: Our in-house factory utilizes both manual and automated assembly methods. For prototypes and small-batch projects, manual wire harness assembly can save equipment setup time. For large-batch projects, automated assembly equipment enhances efficiency. Both assembly techniques allow us to respond rapidly to customer demands.
Fiber Optical Cable Assemblies
Fiber Optical Cable Assemblies
Coaxial Cables
Coaxial Cables
Halogen Free Cable
Halogen Free Cable
ETFE-, FEP-, PFA-, Cables and Wires
ETFE-, FEP-, PFA-, Cables and Wires
Custom Cable Harness
Custom Cable Harness
Ribbon cable
Ribbon Cable
Electromechanical Assemblies
Electromechanical Assemblies
Stainless and synthetic cables
Stainless and Synthetic Cables

Harness Assembly Process

Founded in 2004, FS Technology has been committed to precise manufacturing processes throughout its two decades of operation. Let’s take a closer look at how FS Technology accomplishes its electrical harness assembly process!

Each cable and wire must adhere to the geometric and electrical requirements of the connecting devices. Each cable and connector should be configured to match the precise length, dimensions, and layout of the main product they are connecting to. This precision in cable assembly is both crucial and challenging. Sometimes, for the sake of assembly and maintenance, it’s beneficial to color-code the cables and apply labels.

Before commencing the processo de montagem, it is essential to prepare the components and understand their purposes to ensure smooth transmission of electrical signals and power. Wires and cables serve as conduits for the flow of current and signals between various components within an electronic system. Connectors establish secure and reliable connections between wires and various electrical components, while terminals provide secure connection points between wires and connectors, reducing signal interference. Sheaths and conduits protect wires and cables from moisture, wear and tear, and mechanical damage. Clamps and fasteners prevent cable entanglement and facilitate neat and efficient arrangement within the equipment.

Prior to assembly, it is necessary to use CAD software to design the cable layout and lengths, selecting appropriate components based on application requirements. During production, wire-cutting machines cut wires to the required lengths, and wire strippers remove insulation from the wire ends. Once the cable assembly is prepared, wire crimping machines are used to crimp terminals onto the wire ends, and the assembly is constructed as per the design. The entire process is automated, and these machines operate according to predetermined programs, ensuring efficiency and overall quality. After the cable assembly is completed, necessary tests are conducted to ensure compliance with electrical and mechanical requirements.

Testing processes encompass quality control throughout the production stages and final inspections. Experienced operators conduct periodic quality checks and visual inspections at various production stages to ensure the integrity of the insulation and the quality of terminal crimps. After production, essential electrical and mechanical tests are carried out to ensure proper wire connections and functionality in various extreme environments.

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