Wire harnesses: Solutions for reliable connections

Wire harnesses and cable assemblies are two concepts that often confuse users. While both are used to transmit signals or electrical power, they differ significantly in complexity and purpose.

1.1 What are cable assemblies?

Cable assemblies refer to a group of cables bundled together, often with connectors or terminals at the ends, designed to be installed as a single unit. Cable assemblies are commonly used to connect different components within an electrical system. The primary purpose of cable assemblies is to ensure that the cables are properly terminated and ready for easy installation and connection.

Cable assemblies are tailored to perform specific functions, depending on the connectors, plugs, or terminals located at each end. They are used in a wide range of applications, including flat panel displays, automotive electronics, integrated cockpit systems, and even simple LED accessories.

1.2 What are wire harnesses?

Wire harnesses, also known as harnessing cables, are more than just a bundle of cables. They include protective elements like ties, sleeves, or tubing to safeguard the wires from environmental factors such as moisture, temperature fluctuations, or friction. The purpose of wire harnesses is to transmit power and signals between components or systems while protecting the wires from environmental factors such as heat, humidity, and motion. This ensures safe and efficient wiring in devices and machinery. Wire harnesses are typically tailor-made to suit specific applications and environments.

The primary difference between cable assemblies and wire harnesses lies in their function and complexity. Cable assemblies simply create a connection path between one point or circuit and another. In contrast, wire harnesses can connect multiple points or circuits and may branch off into several directions, each performing distinct functions with multiple connection points along the way.

Using wire harnesses provide the following benefits:

• Improved reliability and safety: Wire harnesses enhance system reliability by providing secure and organized connections, reducing the risk of loose connections, short circuits, and other electrical issues. This also contributes to increased safety by lowering the chances of fire hazards and other risks caused by improper electrical connections.
• Enhanced functionality and efficiency: Wire harnesses can be customized to meet the specific requirements of each application, providing the necessary functionality for complex systems. Additionally, wire harnesses improve efficiency by reducing installation and maintenance time and effort.
• Simplified maintenance: Wire harnesses centralize all electrical connections, making it easier to diagnose and troubleshoot problems, thus reducing downtime and maintenance costs.
• Cost effectiveness: Using wire harnesses helps lower costs by eliminating the need for manual wiring, saving time and labor, and reducing the risk of errors and rework expenses.

At HELUKABEL, we offer wire harness solutions tailored to meet the diverse needs of our customers.

4.1 Wire harnesses for bus systems

We provide wire harnesses solutions for bus systems featuring M8 and M12 connectors. These two types of connectors are commonly used in industrial automation, machining centers, and production lines. They form an integral part of the control systems for sensors and actuators, other I/O devices, and valve terminals. Depending on the application, the connectors are available in A-coded versions with different pin configurations.

• Patch Cable M12 for Profibus RS 485, drag chain
• Patch Cable M12W for Profibus RS 485, drag chain

4.2 Wire harnesses for networks

• Patch cable S/FTP halogen free, Cat.6a 500 MHz (10GBit)
• Patch cable U/UTP halogen free, Cat.6a 500 MHz (10GBit)
• Patch cable SF/UTP PVC Cat.5e
• Patch cable S/FTP halogen free, Cat.6
• Patch cable unscreened U/UTP PVC, Cat.6
• Rubber cable reel with HELUKAT® Type copper data cable

4.5 Wire harnesses for fibre optic

Some wire harnesses for fibre optic include:

• Jumper cable I-VH 2x1 (glass fibre)
• Fibre pigtails
• Jumper cable I-V2Y 1P 980/1000μm (POF)
• Jumper cable I-V(ZN)HH 2K 200/230μm (HCS)

>>See more: Fibre optic cables and pre-assembled fibre optic connections

4.6 Customized wire harness solutions

For standard cabling systems in automation, such as industrial Ethernet and M12 A-coded connectors, HELUKABEL always has products readily available for customers. In addition, for specialized applications requiring custom designs, our experienced engineering team is always ready to consult and provide support to deliver products that meet customer expectations.