When planning this crucial equipment component, it's necessary to keep a few fundamental factors in mind when constructing your wire harness. As a result, the procedure will be more effective, and the outcomes will be better. To help you identify the possibilities and create a solution that aligns precisely with your goals, follow these suggestions as you begin your project.
As a manufacturing company, you must buy IPC 620 standard revision c to help you set appropriate guidelines, set processes, standards, and compliance in cables and wire harnesses and assemblies. IPC-WHMA-A-620 Revision C, published in 2017, has improvements included that make it simpler. There was also a focus on using images to clarify important ideas. In several instances, Revision C aimed to align A-620 requirements with applicable standards from other industries. Revision C, for example, includes specifications for soldering gold cup terminals following J-STD-001. A portion of Revision C complies with IPC-A-610, "Acceptability of Electronic Assemblies," as do other parts.
IPC-WHMA-A-620 Revision C also adds sections on raceways, wire seals, grommets, safety wiring, and cable. Additionally, there have been many updates to the section on jack posts. This industry consensus standard, IPC-WHMA-A-620C, comprises 428 pages and over 700 full-color images. 130 business professionals evaluated, endorsed, and disapproved of the adjustments. More than 11,000 persons have received IPC-WHMA-A-620 certification as trainers or users.
Environment-Related Issues
Every harness is designed with various considerations in mind, the environment it will be used in being one of the most important. For example, fires that run close to an engine or exhaust are subjected to intense heat, while other harnesses may be exposed to chemicals, water, dirt, or oil.
Similar to how some wire harnesses must maintain flexibility or are continually subjected to abrasion, which can be brought on by vibration.
For your application, choosing the right type of wire can be crucial. Using the incorrect wire can result in wire insulation breakdown, which can cause failures, safety problems, or noncompliance with standards like UL, CSA, or CE.
Considerations for Parts
You'll probably be including a list of parts when sending designs to an outsourcing partner like the contract manufacturer. Make sure you give a mechanism for the outsourcing company to cross reference your part numbers with a manufacturer and a manufacturing part number if you have your own component numbers on your drawings. It's helpful to indicate "or equivalent" on your parts list if a part (or parts) are not required to be a specific brand or type so the contract manufacturer can, if possible, substitute with alternatives that could improve the delivery, performance, or cost of the harness.
Your outsourcing partner will require access to any internal harness specifications or production guidelines you may have if they want to come up with the best solution. Typically, these specifications specify how the harness should be ended, identified, wrapped, and other things. Reviewing the IPC/WHMA-A-620 can serve as a collection of general standards customized to meet your needs if you don't already have one and would like to create one.
Before Design, Work On This Additional Information
Knowing all of these will help you choose the right materials and design criteria:
Tolerances and lengths: Be precise with your measurements and tolerances. Some OEMs measure from the connections' front, while others measure from their back. What length tolerances are considered acceptable?
Covering: There are numerous types, including braided loom, Tape, conduit, and split sleeve; each has a unique function as well as benefits and drawbacks of its own. Before choosing which is suitable for your application, be aware of each function. Don't forget that not all of your wire may need covering or be better off without it, depending on whether flexibility, troubleshooting, or serviceability are more crucial.
Splice Locations and Splicing: A wire or electrical circuit can be spliced in various ways. Before creating your harness or submitting your ideas to a manufacturer of wire harnesses, consider the advantages of each one in the multiple situations where they are applicable.
Wire Labeling and Color: Keep track of the colors of your wires and any text you wish to label or print on them to aid in identifying circuit names.
Type: There are numerous types of wire, each suited to a different function, with variations covering voltage ratings, insulation type, bare or plated copper, etc. For instance, UL1015 (MTW) wire is frequently used in electrical control panels, whereas GXL wiring is highly typical for automotive wiring.
Connections, Seals, and Terminals: Additionally, there are numerous kinds of connectors, seals, and terminals. It should be noted that many connections may handle a variety of terminals and seals, each designed to work with a particular wire gauge, wire insulation thickness, or terminal plating. Some connectors also need extra accessories or components to lock terminals into position. Call out the appropriate locks and any additional equipment you need, such as backshells, plugs, strain reliefs, caps, etc.
Labeling: If you need labels on connectors to help you identify them, mention them in your drawing or include them in the harness specification.
Testing: Numerous test methodologies can be used. While some applications only need a straightforward continuity test, others might call for the wire to pass a high-voltage test. Think about what is appropriate for your application.
It can be difficult to assemble an electrical package schematic, cable and harness layout, and service documentation for your project with all the necessary information. It necessitates a thorough understanding of all the constituents and impacting elements, not the least of which are the demands and constraints of the electrical system. A contract manufacturer with expertise in electrical assembly can streamline the production process and improve the quality and effectiveness of the finished product.
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