In the modern industrial system, there is such a seemingly ordinary yet crucial component—it is like the nervous system in living organisms, silently undertaking the core tasks of signal transmission and power delivery, supporting the normal operation of various equipment. This is the wire harness. From the smartphones and home appliances we use daily, to cars running on the road, airplanes soaring in the sky, and even precision industrial machine tools and medical equipment, wire harnesses are everywhere, serving as the "lifeline" that ensures the efficient and stable operation of various electronic and electrical systems.

I. Definition and Core Components of Wire Harness

A wire harness, also known as a cable harness, is an integrated cable assembly formed by arranging multiple wires and cables in a certain order and then binding or wrapping them. Its core function is to connect different electronic components into an organic whole, realizing power supply and signal interaction, and ensuring the coordinated work of all parts of the system.

A complete wire harness usually consists of wires, connectors, insulation and protection components, and auxiliary components. The detailed structure can be understood through the following diagram of terminal insertion into the sheath, which shows the key connection part of the wire harness.

II. Application Fields of Wire Harness: The "Connection Hub" from People's Livelihood to Industry

The application range of wire harnesses almost covers all electronic and electrical fields. Wire harnesses in different fields have significant differences in design and manufacturing due to the differences in use environment and functional requirements.

1. Automotive Field: The "Largest Market" for Wire Harnesses

Automobiles are one of the most extensive and complex application fields for wire harnesses. The body main wire harness assembly can be divided into three segments: outer cabin harness, instrument harness, and inner cabin harness. The following figure shows the segmentation of the body main wire harness assembly.

For new energy vehicles, high-voltage wire harnesses are a key component. Internationally, high-voltage cables are protected with bright orange outer skins or sheaths, which not only have good insulation but also have necessary warning effects. The following figure shows the high-voltage wire harness of a new energy vehicle.

2. Other Fields

In consumer electronic products, wire harnesses present the characteristics of "miniaturization, lightweight, and high density". In industrial automation equipment, they need to withstand harsh environments. In medical equipment, they must meet strict certification standards.

III. Manufacturing Process of Wire Harness: Precision Control from Design to Finished Product

The manufacturing of wire harnesses is a precision process integrating design, processing and testing. Key processes include design and development, wire processing, wire harness assembly, inspection and testing. During the wire processing stage, crimp height measurement and pull test are important quality control links, as shown in the following figure.

When assembling the wire harness, tape winding is required. The tape should be fully wrapped around the corrugated tube on the wire, with 1/2 overlap between tapes, and the surface should be smooth after winding.

IV. Future Development Trends of the Wire Harness Industry

Driven by trends such as new energy, intelligence, and lightweight, the wire harness industry is ushering in new development opportunities and challenges, showing trends like high voltage and integration, lightweight and new material application, intelligence and digitalization, high speed and anti-interference.

In conclusion, as the "nervous system" of electronic and electrical systems, wire harnesses are often hidden inside the equipment and not noticed, but their importance is self-evident. In the wave of continuous technological progress, the wire harness industry is also continuously innovating and upgrading, providing a solid connection guarantee for the development of various emerging industries.