Wire Harness Design & Manufacturing
Wire harnesses transmit signals or electrical power in a wide range of equipment, tools, and vehicles which includes industries such as appliances, heavy equipment, medical equipment, defense weapons, and electronics. They’re made from groupings of cables, wires, and subassemblies. At their most basic, wire harnesses are constructed from three components, wires, terminals, and connectors, but they can become highly complex to handle multiple branches, safety features, and termination points.
Custom wire harnesses are the core of electronic applications. Manufacturers must build precise wire harness designs to ensure their products run efficiently and reliably.
Primo Corporations have the ability to build tooling for injection molding to make different connectors according to customer’s requirements, and we have a strict QC process to ensure quality. We will respond quickly to your ever-changing needs and requirements. We deliver wire harnesses and cable assemblies faster. Custom wire harnesses are the core of electronic applications. Manufacturers must build precise wire harness designs to ensure their products run efficiently and reliably.
From start to finish, you can count on Primo Corporations to fulfill the client needs of design and execution of the desired project. Even if its within a potentially slim budget, you can be sure Primo Corporations will follow through and meet the goals and satisfy the client expectations.
Design and Manufacturing Process
Every wire harness needs to match the geometric and electrical requirements of the device or appliance for which it’s used. Wire harnesses, typically, are separate pieces from the larger manufactured components that house them. This brings a number of benefits, which include:
- Simpler manufacturing processes by creating wiring for drop-in installations
- Easy disconnecting and analysis for troubleshooting, disassembly, or part repair
- Simple installation processes with wire harnesses that include all of a product’s wires, cables, and subassemblies with quick connect/disconnects.
Each wire and terminal can be configured to match the exact dimensions and layout of the main product it is connecting to. Wires can also be color-coded and labeled to streamline installation and maintenance.
The manufacturing process starts with the design and schematic development. It then moves to the prototype. Finally, it goes into production. Operators assemble wire harnesses on drawn-out test boards which confirm precisely measured wire lengths. The board also confirms that the designed terminal and connector housings that suit the application is being used, cable ties and coverings are added for easy organization and transport.
Although automation plays an important role in all manufacturing processes, the complexity of the end product means that many sub-steps of the assembly process must be done by hand. Wire harness cable assemblies are multifaceted processes. The main steps of this process include:
- Installation of the wires, terminals, and connectors on the building board
- Installation of specialty components such as relays, diodes, and resistors.
- Installation of cable ties, tapes, and wraps for internal organization
- Wire cutting and crimping for reliable terminal connection points
Primo Corporations has the ability to build tooling for injection molding to make different connectors according to customer’s requirements, and we have strict QC process to ensure quality. We will respond quickly to your ever-changing needs and requirements. We deliver wire harnesses and cable assemblies faster. Custom wire harnesses are the core of electronic applications. Manufacturers must build precise wire harness designs to ensure their products run efficiently and reliably.
It’s vital to Primo Corporations that our customer feels their expectations are met and the quality of the product if very important to the process from start to finish. Customers should feel complete confidence in our ability to deliver an exacting product result.
Applications and PMCI’s Specifications
Almost all electronic devices and appliances require wire harnesses to transmit electricity and signals. Wire harnesses simplify manufacturing and maintenance processes in residential, commercial, and industrial contexts. Common applications for wire harnesses include:
- Washing machines, dryers, refrigerators, and other household appliances
- Consumer and commercial electronics
- Automotive Equipment
- Commercial and industrial machinery
- Medical equipment and other electronic devices
In order to fully meet the diverse array of needs and regulations required by their applications, wire harnesses must incorporate dozens of distinct features and capabilities.
Here at Primo Corporations, we offer precision quality for our wiring harness assembly processes:
- Integration of multiple wire and cable types
- Custom configuration
- Accelerated installation time
- Application of multiple interconnects
- 100% fit, form, and function validation
- High-speed automated wire processing
- In-line wire and cable marking
- Harness subassembly prefabrication
- Ultrasonic welding for in-line wire splicing
- Wide range of component options
- Reverse engineering
- Unlimited combinations
Industrial facilities often require unique wire harnesses that conform to industry building standards such as UL compliance with fire safety regulations. Infrastructural components (such as public transit controls and bus timers) require fast responsiveness and a high degree of accuracy. At PMCI, our kits and wire harnesses are custom created to meet our clients’ specific needs without delay.
Complying with safety standards is an important aspect of wire harness design and assembly. PMCI’s wire harness facility is ISO 9001:2008 certified for safe wire harness manufacturing. Our operators are certified to IPC WHMA 620 standards, and our soldering operators are certified in J Standard 001. We also build to UL standards.
Start Your Wire Harness Assembly Process Today!
Custom wire harness assemblies are an integral part of reliable residential, commercial, and industrial electronic systems. If you would like to learn more about how we can bring our unique expertise to your next wiring system, contact us today or fill out our online form to request a free quote.