Wiring requirements vary from individual to individual. Your wiring application area and functionality will dictate the design, voltage, and current capability, size, colors among other variables. Therefore, it is essential to deal with a China wiring company that takes your needs seriously.
Apart from meeting customer’s requirements, China wiring is under certain standards on safety, design, and installation. The rules and regulations are formulated by GB standards (GuoBiao Standards), China Compulsory Certification (CCC), and the International Electrotechnical Commission (IEC).
The IEC tries to harmonize the wiring standards globally. It has proven difficult as every country varies environmentally and structurally regarding electrical appliances, machines, and automobiles. This article will provide detailed information on China’s wiring. From wiring and cable harnessing, color codes, designing, testing, and other wiring processes.
Table of Contents
CHAPTER 1: Cable Harness
Cable harness is combining of two or more conductors that are insulated with a more intensive exterior product. Mostly, a cable will have a positive wire to carry current and a neutral one to complete the electrical path and finally a grounding wire. After that, the whole combination is covered with heavy-duty materials such as shrink-wrapped thermoplastic, rubber or vinyl sheath.
Cable harnessing is mainly a custom-designed assembly to ensure the overall product meets your specific logistic and structural requirements. Also, other factors are put into consideration, for instance, temperature, humidity, size, shape, chemical substance exposure, fiction, colors and area of application.
We deal with highly qualified electrical engineers in designing cable harnesses thus ensure quality from the start. After that, it is our sole responsibility to test that every harness will provide its optimum function. We confirm its durability under different environments, desired functionality and the place of application. In the end, we come up with quality-defined standards of manufacturing a cable harness.
Aside from acquiring standard processes, we also develop a methodology in which we develop some of our tools, plastic, dies, and glass, metal, and synthetic materials. To bring all the materials and tools together, we have a highly designed and developed process with qualified technicians to see that the manufacturing process goes on smoothly and efficiently.
1.1 Cable Assembly process
The cable design process entails:
- Cutting and shaping cables to the required lengths
- Installing the wires, cables, and components (subassemblies) on the assembly or pinboard
- Routing and attaching subassemblies with terminals and through other connector housing or sleeves
- Attach the subassemblies to the board with wraps, weaves, ties, or tapes
- Where possible, soldering of wire ends with a solder machine
Nevertheless, this is just a general process of what cable assembly entails and not the specific step to step process. Also, automation of the whole process has proven difficult as manual cable harness is more cost effective considering the numerous activities involved. However, initial parts of harnessing and kitting can somehow be automated.
In the end, we have a complete functioning and high-quality product for your use. The whole china wiring harness involves a balance of accuracy and speed ensuring every item meets the standard protocols.
1.2 Cable Harness Testing
Before releasing the wire harness to you, we ensure the cable harness meets the geometric and electrical requirements by thorough testing and evaluation by our experienced team. Repeat purchase of similar products over the years has allowed us to develop standard product and save time in harnessing process, testing, and installation.
What is Automobile Wire Harness?
Automobile wire harness can simply be described assembling of electrical cables for transmission of signals (wire harness) in automobiles. Wire harness plays an important role in some functionality of automobiles and space/air-crafts considering the amount and length of wires involved in their construction. Wire harness ensures the wires are more bound thus safe from damage through abrasion, vibrations, and moisture.
Also, the constriction of the wires saves much space, and since they are bound into slave resistant-sleeves, the possibility of electrical fires occurring is minimized.
CHAPTER 2: China cable Harness Heat Shrink Tubing
Cable harness unlike wire harness as you will see later requires more great insulating materials. It involves bundles of wires and cables, and the connections are made for sensitive machines, automobiles or aircraft. Therefore, caution and precision are mandatory.
2.1 Protecting Cable Harnesses
This is an efficient insulation technique especially when the cable harness is used in an environment with diverse temperature levels. Plus, it can be useful in handling chemical erosion, abrasion or even water damage.
This is a technique that allows the flexibility of the cables and wires in the harness. It involves a wrap tubing with openings that provide passage for the assemblies to join or separate from one group to another.
Split loom tubing:
The loom tubing is a method that ensures the connections remain intact. The tubing has small openings along its length. Through these slits is where the wires and cables are installed and after installation, they close keeping the assemblies surrounded.
This method deals with sleeves especially those made with braided-like material such as polyethylene, these allow flexibility at severe low temperatures. Also, some sleeves expand in situations where a lot of wrapped wires are involved.
Use of tapes in designing cable harness is among the standard parts of the process. However, it can also be automated. The tapes can be of different backing such as cloth, foam, PVC or felt.
In the above techniques of insulation in China wiring, the heat-shrink tubing has proved to more effective at providing cover against damage. It is a recommendable method for a cable to either a manufacturer or you.
2.2 Features to Consider in Heat Shrink Tubing
The heat-shrink tube as a product has different brands. Some offer one unique feature while some have combined benefits, and it is up to you to choose one that suits your needs best. Here are separated characteristics a heat-shrink tube could offer:
This is suitable tubing if the cable harness is to be used in an environment of extreme temperatures, cold or heat. For example, in an automobile or a factory machine where much heat is likely to be emitted.
Chemical resistance: You should know what type of chemicals and the level of concentration they are in, your harness will be exposed. They can either be acidic or basic, after that, you can choose a tubing that provides the proper protection against that chemical damage.
This is a feature to consider especially when your cable harness will be exposed out in public. The tubing material should, therefore, be brawny enough to make it difficult to impregnate the wires.
Abrasion resistance: Friction will majorly be as a result of movements in the area of application of the cable harness. Consequently, erosion and heat will be the result. Therefore, other than being abrasion resistant, the tubing material ought to be able to withstand heat. It is significant considering the damage and loss that can occur if the wires got exposed in a condition of extreme heat.
How much voltage will pass through your cable harness wires? The number of voltages is essential because it helps Chinese wiring manufacturing use wires that can handle the current.
The flexibility depends on the size of your insulated wire harness and the area in which the cable harness is installed. Flexibility in tubing ranges from very elastic to rigid, and it is up to you to choose which one suits you.
Assuming you need a cable harness for a watercraft, water-resistant tubing is what you should go. However, in consideration of what type of water the harness will be in contact with, is it fresh or salt water?
No, this is not similar to flexibility. It understands the degree of shrinking that can occur and finding the material that has the ratio to withstand the change.
If your cable harness were exposed to sunlight for a long period, UV- resistant tubing would be very useful.
In a more severe environment with flames involved, apart from the temperature-tolerance feature, tubing that is flame resistance can come in handy in protecting the cable harness.
CHAPTER 3: China Wiring Color Code
IEC has been trying to standardize wiring color codes. However, colors still vary from region to region. The variation is especially in jurisdictions where some wires are codified with an allowance of alternative wire colors to use.
Most of China wiring follows the International Electrotechnical Commission (IEC). With AC wires such as flexible cables (lamp cords and extensions) and fixed wires (behind or on the wall cables), the protective earth or insulation is green or green with yellow strips. Neutral is indicated with blue. China wiring of live wires is indicated as brown, black and grey labeled as L1, L2, and L2 respectively.
DC China wiring such as in solar power and computer data centers follows similar standards as the AC wiring.
CHAPTER 4: China Wiring Harness
Unlike cable harness, china wiring harness deals with connecting single conductors. Wire insulation has little effect in protecting it unless in a situation where the wires are thick as they are at higher risk to damage from a burned fuse. Also, jacketing is mainly employed on wires to be used under conditions of dust, extreme temperature, moisture and friction for example in a remote or housing shell.
Wiring harness integrates wiring components into a single unit thus simplifying the manufacture of a huge complex writing system. Also, it allows for an easy-fix installation and modification in case of damage to some components.
Therefore, China wiring involves assembling of different wires that may or may not have the exterior covering. Wire harness is a cost-effective means in creating an orderly and carefully fitted wiring system. In order to achieve an effective harness design, there is a need for evaluation of different types of cables you use, style and materials.
- Insulating colors
- Color codes
- Shielding and heat-shrinking coats
- Lacing and wire-tires
- Labeling and barcodes
- Polypropylene, nylon, and paper fillers
Additionally, the area of application of the wire harness should be known and considered. It includes factors such as size, chemicals that will get in contact with the harness, temperature, humidity, and friction. These variables will facilitate the creation of the design model regarding size and components the harness will use.
We aim to build our customer a long-lasting, durable, affordable and quality product. Thus, we employ our best technician, tools, and technologies in assembling cables, connectors, pins, and other materials.
4.1 China Wiring–Wire Harness Design
After building the harness design model, designing begins with the development of a blueprint for manufacturing and a pin board for hosting the harness. The pin or assembly board is a representation of the harness. It indicates all the components; their location as well serves as a working table for the wire harness.
The wires to be assembled come in a master reel then cut into the desired lengths and printed for labeling and bar-codes where required. With the required lengths, the wires are stripped off at the end to fit the terminals and connector housing where necessary.
The wires are placed on the assembly board and attached to it with the suitable lacing, wire ties, tapes, strings, weaves or straps or a combination of the components.
Over time there have been attempts to advance manual wire harness designing to automation, but as the process involves many activities, most of the stages of the process remain to be manual. Nevertheless, some parts of the process have been automated for speed and accuracy.
4.2 China Wiring–Wire Harness Testing
Once wire harnessing is concerned, the process is not complete until testing for the real world application is done. Testing is usually conducted with our expert staff who employ the help of a test board.
A test board evaluates the electrical functionality of the wire harness. It is preprogrammed with electronic features, and once the complete wire harness is connected, it provides results of its performance or in comparison to certain values.
CHAPTER 5: What to look for in China Wiring Manufactures
Wire or cable harness may seem like a typical job until you come to think of it regarding what and how much you could lose in case there is an application of poorly manufactures cable harness. Damage or failure of a wire harness could have an impact on the devices connected to it. Consequently, it is essential that you have sufficient information on choosing the right manufacturer for your harness.
Tips for Evaluating Wire Harness Manufacturers
The quality, durability, and life of your wiring harness will have a lot to do with the manufacturer. Below are tips you can put to considerations to enable you to choose the suitable manufacture as you do your research.
China Wiring–The company history
A manufacture’s longevity in China wiring is an assurance of a well-versed provider in the wiring harness. More time spent in the industry means there is an accumulation of knowledge, skills, practices, better methodologies and acquisition of quality materials.
Also, it would help if you did not have to worry about finding out that your manufacture closed the business without getting the job done. Like every industry, businesses start and get closed; a more rooted china wiring manufacturer will advantageously have you at peace.
Skill level and experience
As earlier discussed, it has become impossible to automate the whole wiring harness process. Therefore, standardization is less achieved with manual working thus making it easy for you to identify a quality finished product. It will depend on the level of expertise of the designers and manufacturers.
Quality control is also an aspect you can consider about you manufacture. It is mainly implemented during testing. Therefore, the company should have invested in high testing technology. Efficient and optimal testing is a guarantee that your requirements of a quality and reliable wiring harness will be met.
China Wiring–Does the company cost complement the quality?
It is human nature to relate expensive with quality. However, your wiring harness manufacture should be able to meet your component, and product quality needs such that you will be happy to pay for it. Low cost of the service and the product could seem like a great deal but look out, it does not come to bite you in the back.
Proper communication and interaction
Apart from working to achieve a quality product, the manufacturer should be attentive to your specific needs and put them in action. Additionally, when you reach out, the manufacturer should respond immediately and address your concerns. Communication should not be frustrating.
Wiring whether wire or cable harnessing, it is a task that requires expertise and experience for a quality end product. We at Wringo, we are committed to providing outstanding wire harness solutions. Through our expert technicians who understand and are familiar with the required standards of China wiring, we deliver nothing short of the best.
With years of experience at wiring and manufacturing of related materials, we have mastered the skill and perfected the art of understanding your ideas and making them come to be. Contact us any time; we will be glad to serve you.