Manufacture of wire harness for harsh operating environments

01 High Temperature

Wire harness exposed to high temperatures are at risk of several issues that can affect their functionality and safety.  Insulation may degrade, become brittle, crack or even melt.   This can result in a short circuit or electrical failure.   Conductors may expand due to heat, potentially loosening the connection and causing intermittency problems.

High temperatures speed up chemical reactions that degrade materials and cause corrosion.   In severe cases, overheating can cause flammable components to ignite, creating a fire risk.   In order to solve these problems, it is important to use heat-resistant materials and incorporate effective thermal management in the harness design.

Solution:

Materials: Some examples of heat-resistant materials include polyimide (PI), polytetrafluoroethylene (PTFE), or cross-linked polymers that can withstand high temperatures (up to 400°C in aerospace).

Thermal management: Apply heat dissipation strategies, such as using heat-resistant conduits, wiring away from heat sources, or incorporating thermal barriers.

02 Low temperature

The main problem here is the brittleness that can develop in the insulation materials, making them more prone to cracking or breaking under mechanical stress. This can lead to exposed wires, which increases the risk of short circuits or electrical failures. Low temperatures can also cause the material to shrink, which may loosen the connection, leading to unreliable performance or intermittent failure.

Some materials may lose flexibility, resulting in increased strain during movement or vibration, further exacerbating the risk of damage. To reduce these risks, it is important to use materials specifically designed to maintain flexibility and durability in cold environments.

Solution:

Materials: Suitable materials include silicone or fluoropolymers that remain flexible in cold environments. Ensure that all materials, including connectors and insulators, are rated to the lowest possible temperature as expected.

03 Moisture and water exposure

In environments such as Marine or industrial environments, waterproof belts are crucial because they can be exposed to high humidity, rain or even direct immersion in water. Moisture can seep into the harness, causing short circuits, corrosion of metal components, and potential electrical failures. Saltwater, especially in Marine environments, significantly accelerates corrosion and poses a more serious threat.

Solution:

Materials: Materials such as polyurethane (PUR) or neoprene are used as outer sheathing to provide a barrier against water intrusion.

Design: For waterproof wiring harnesses, the branches must be cross-wound to ensure that the wiring harnesses remain fully covered. If a waterproof rubber ring or through-hole rubber sleeve is used, the seat belt portion should be enclosed first. After that, the rubber ring or casing should be securely wrapped around the seat belt using a double wrap technique.

Connectors: Choose sealed or clad connectors to prevent moisture from entering critical areas. Select connectors with IP67 or higher protection for high humidity or immersion environments.

Conductor: Tinned copper or other corrosion resistant alloys help protect against the damaging effects of water and salt. If weight is a concern, consider aluminum. It is lighter than copper and is used in aerospace applications, requiring special terminations to prevent galvanic corrosion.

04 Chemical Exposure

In industrial Settings, wiring harnesses are often exposed to chemicals, oils and solvents that degrade insulating materials. This degradation can cause brittleness, cracking, or swelling, which can compromise the integrity of the harness and increase the risk of electrical problems.

Solution:

Materials: Use insulation materials known for their chemical resistance, such as PTFE, ethylene tetrafluoroethylene (ETFE) or fluorinated ethylene propylene (FEP). Consider applying additional protective coatings to increase resistance to harsh chemicals.

05 Mechanical stress and wear

Wiring harnesses in industrial, automotive or aerospace environments are subject to mechanical stresses such as vibration, movement and wear. These forces can wear down the insulation, resulting in exposed wires, short circuits, or even complete failure.

Solution

Wear resistant jackets: Choose materials with high resistance to mechanical wear, such as crosslinked polyethylene (XLPE) or thermoplastic elastomer (TPE).

Stress relief: Components such as washers, clamps, and cable ties are added to reduce stress on wires, especially at connection points and areas that move frequently.

Protective conduit or hose: This will protect the harness from physical damage and reduce the effects of vibration.

06 EMI and RFI

Wiring harnesses can pick up unwanted signals or interfere with other electronic systems in environments with severe electromagnetic interference, such as near heavy machinery or aerospace applications. This can result in data corruption, communication errors, or equipment failure.

Solution:

Use shielded cables with braided or aluminum foil shielding to protect against EMI and RFI. Proper grounding of the shield is essential for effective noise reduction.

Twisted pair wiring: The implementation of twisted pair wiring signal lines to eliminate electromagnetic noise.

Grounding: Make sure all wiring harness components are properly grounded to prevent static buildup, which can exacerbate EMI problems.

Why Choose JMTO as Your Custom Wire Harness and Wiring Harness Assembly Supplier?
JMTO has been manufacturing custom wire harnesses and wiring harness assemblies to the highest quality standards, and we also provide exceptional value-added services to provide the best value to our customers.  JMTO offers the following value-added services

■.Wire Crimping                                                   ■.Wire Termination
■.Wire Stripping                                                   ■.Wire Cutting
■.Wire Identification/wire marking/labeling          ■.Wire Processing 
■.Wire Solder                                                       ■.Wire Handling

■.Wire Taping & Insulating                                   ■.Wire Heat Shrinking

Thanks to JMTO's long production history and high production demand, our supply chain has a competitive advantage in allocation, delivery and price.  

We can provide OEM and ODM services according to customers' needs.  wire harness and cable assembly can be widely used in UAV, medical, automotive,automation equipment, power, industrial equipment, home appliances and consumer electronics industries and exports to the United States, Europe, Japan, South Korea and other countries and regions.  

Contact JMTO for Turnkey Custom Wiring Harness Solutions

If you have any questions, please contact us and we look forward to hearing from you. We have long experience in manufacturing wiring harness assemblies and cable assemblies for various industries.