Wire harness processing Terminology and definitions

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SAISONIC specializes in the manufacturing of wire harnesses and the processing services of custom cable assemblies.  Many of our clients outsource their wire harness assembly projects.  During this process, it is important to standardize and define some communication terms of wire harnesses and cable assemblies to clarify what they mean. The following list includes some wire harness terms and definitions.  You will find these wiring harness terms very helpful.  Especially if this is brand new to you. All the following wiring harness provisions are from the industry standard IPC/WHMA-A-620, which also provides standards for commonly used wiring harness components.

1.  Wire and cable

Wire:a slender metal strip or fine wire.

Cable: A group of separately insulated conductors.  However, these conductors are twisted or connected in parallel under a common sheath.

American Wire gauge (AWG) : A standard system for specifying the diameter of wires.

Braided: Bare metal or tin-plated copper wire braided, used as a shield for wires and cables. This type of wire is commonly used in heavy industrial equipment or in harsh operating environments, such as agricultural machinery. Braiding will provide additional protection for the cable.

Conductor: Uninsulated wire.  The conductor of an insulated wire, used for transmitting electric current

Ribbon cable: A flat cable in which separately insulated conductors are laid in parallel.  These conductors are also bonded together through adhesive laminates.

Wire diameter: The thickness of the main conductor plus the insulation layer

2.   Connectors and terminals

Connector: A device used for electrically connecting two or more conductors.

Terminal: A device designed to terminate a conductor. It should be affixed to a post, stud, chassis, another conductor, etc.  Therefore, this establishes an electrical connection. In addition, some types of terminals include: rings terminal, tongues terminal, spade terminal, flag terminal, hook terminal, blade terminal, quick disconnect terminal, copper lug Terminal,offsets and flanges.

Contact : the conductive part of a connector. Therefore, it works together with another such component to complete or disconnect the circuit. So they will be divided into male and female.

Crimping height: Measure the overall height of the wire tube after crimping the terminal.

Double crimping: The process of mechanically crimping two or more times at the same position of one terminal.

Ferrule:A short tube. Useful in making solderless connections to shielded or coaxial cable. Also, a terminal crimped onto stranded wire to allow insertion into terminal blocks.

RF connector: A connector used to connect or terminate coaxial cables.

Strain relief: A technique or project that reduces the transmission of mechanical stress to the ends of a conductor.

Insulation crimping :The area formed around the insulation of a wire by terminals, joints or contacts.

Bellmouth:The raised part at the front and/or rear of the coiled reel. Therefore, this provides a progressive entry and exit wire strand without causing damage.

3. Wiring Harness Clauses 

Wiring harness: A group of wires and cables. Seat belts usually burst. Circuit breakers are tied together or pulled into rubber or plastic sheaths. Therefore, the wiring harness provides the interconnection of circuits.

Cable assembly: Cables with plugs or connectors.

4. Various useful terms and definitions

Conduit: A pipe through which insulated wires and cables pass.

Dielectric medium: any insulating medium between two conductors.

Grommet:A rubber seal. This is useful on the cable side of multiple contact connector. Furthermore, it seals the connector against moisture, dirt, or air.

Insulation: Materials that provide high resistance. This makes it suitable for covering components, terminals and wires. This coverage will prevent possible contact between adjacent conductors. Prevent short circuits in adjacent conductors.

Lanyard: A device connected to certain connectors that allows for separation. It also allows for the separation of half of the connector by pulling the wire or cable.

Stress relief :A pre-determined amount of relaxation to relieve the tension of components or leads.

Tube: A tube made of extruded, unsupported plastic or metal material. For example, heat shrink tubing, insulating sleeves, etc.

Wire Cutting:In this step, the wires are cut to the required length using a wire-cutting machine.

Stripping and Connections:In this step, the wires are stripped to attach connector modules, housings, or terminals.

Soldering：used in some connections, involves melting a filler metal (solder) to join metallic surfaces