Common Problems In Cable Assemblies And Wire Harnesses

While the terms wire harness and cable assembly are used interchangeably and they serve similar functions. Both wire harness and cable assemblies are used by different industries for various purposes and both can face issues that need troubleshooting in order to function optimally. A wire harness or a cable assembly can face issues with poor harness layout, or defective crimping process, and much more. These problems can be solved by laying the wires properly or using a cable crimping tool in Jacksonville to fix them.

Although most of the problems in a cable assembly can be fixed easily, they are still prone to a number of problems. In this blog, we will break down some of the most common problems associated with a wire harness or a cable assembly.

Incorrect Cable Selection

The cable or the wires that you are selecting for a cable assembly needs to be suitable for the environment that you will be using the cables. If not selected adequately, the cables will underperform, misperform, or fail altogether. The cables and wires that are chosen need to be sturdy enough to endure the forces within the environment. A wire that is too weak will break easily and cause disruption in the connection.

Improper Testing

When a cable assembly is first set up, it needs to undergo several tests to make sure that all the connections are done right and it is working properly. If the testing isn’t done properly not only will it lead to faulty functioning but also dangerous defects. The wire assembly needs to be tested until it is 100% sure that it is working properly, especially if the cables involve electrical connectivity. 

Incorrect Prepping

The harness needs to be prepared and staged properly before it is run for operation. Preparing the wires involves cutting the wires to the specified length and stripping the ends properly. Use a coax stripping tool in Orlando for clean and proper wire stripping. Many industries also use automated wire stripping machines but in such machines, user error and poor adjustments can lead to problems in stripping the wire. Before you use an automated machine, ensure that you are using the right size of wire and have also adjusted the machine properly.

Conduct A Pull Test

The cables and wires used in the assembly should be able to withstand the amount of force exerted within the environment. Weak wires will fail under the load and cause disruptions in the application, the assembly will break forcefully and will lose connectivity constantly. To ensure that the wires have the right tensile strength the manufactures should conduct a pull test on the wires.

Improper Layout

If the wires aren’t laid out properly as they are connected to the harness chassis it will lead to a faulty product or may cause the wire lengths to be of extra length and the wires will need to be trimmed. Creating a form board can assist the technicians to lay the wires properly.

Imbalance In Pressure

The right crimp pressure is the proper setting of the die inside a cable assembly. If the die isn’t soldered correctly then it will lead to inner destruction of the assembly and it is commonly seen in the form of fraying. A pressure test before application should clarify the issue.

Incorrect Labeling

This is one of the most common problems faced in a cable assembly or a wire harness assembly. This happens especially in the mass production of cables. A good option to ensure that the harnesses you get are labeled properly is to develop a system that can check the correctness of the labels before they are printed. You can also create sample labels for mock-up products before your harnesses are labeled.

Micro-Fretting

Certain metals, for example, tin and lead if come in contact they lead to oxidation on the surface.  This can cause disruption in the cable assembly, however, intact plating can solve the problem of oxidation.

Defected Crimping

This is one of the most commonly used methods for terminating the ends of the wire. If the crimping isn’t done properly, it can cause short circuits or open circuits in the product. The crimping might even fail spontaneously, so make sure that the crimping is done properly.

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Created on Jun 18th 2021 00:14. Viewed 227 times.

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