The terms "cable assembly" and "wire harness" are frequently used interchangeably, but they actually refer to two distinct products with different manufacturing processes. Sourcing a cable assembly from a wire harness manufacturer (or vice versa) could lead to challenges due to these differences.
Understanding the distinction between a cable assembly and a wire harness is crucial for identifying your specific manufacturing requirements and finding the right supplier. For more information on custom cable assemblies, be sure to check out our manufacturer’s guide to custom cables.
PHYSICAL DIFFERENCES BETWEEN CABLE ASSEMBLIES AND WIRE HARNESSES
The primary physical difference between a cable assembly and wire harness comes down to the complexity of their layout. Cable assemblies are typically point-to-point, single connector cables which sometimes include loopbacks or multiple legs but don’t involve any advanced layout. Wire harnesses, on the other hand, are designed to allow for simple assembly of large, multi-faceted wiring systems. The defining characteristic of a wire harness is its complex arrangement of multiple wires and cables, making it ideal for situations where installing numerous individual cables would be cumbersome.
Wire harnesses are typically pre-assembled and routed by the manufacturer on a board, eliminating the need for installers to manage each wire individually on a crowded production floor. The installer can simply remove the board and install the wires, already arranged in the correct configuration.
Aside from their arrangement and layout, there are no significant differences between a cable assembly and a wire harness. Both can serve the same functions and meet the same electrical specifications, but this simple distinction results in different manufacturing processes.
DIFFERENT PRODUCTS REQUIRE DIFFERENT MANUFACTURING PROCESSES
Cable assemblies and wire harnesses require distinct manufacturing processes, each with its own set of challenges, particularly when produced at high volumes. These differences significantly impact the market dynamics for suppliers.
Cable assemblies are created by attaching cables to terminals at both ends. Suppliers specializing in cable assembly production use specialized tooling for the exact connections required. Many aspects of the cable assembly process can be automated using advanced tooling.
For cable assemblies involving discrete wire, a cut, strip, terminate (CST) machine is used. The machine receives a spool of wire and a reel of terminals, cutting the wire to the required length, stripping the insulation, and crimping the connection—all without manual crimping. In the case of multiconductor cables, automated equipment cuts the cable to size, removes the jacket, and operators apply terminals using tabletop strip/crimp machines.
However, some parts of the cable assembly process still require manual intervention, such as tooling setup, hand soldering, terminal plugging, heat shrink application, cable tie installation, and labeling.
Wire harness production differs significantly from cable assembly production. The process of routing wires and cables onto the board is typically done by hand and can be time-consuming. Suppliers specializing in wire harness production use assembly lines from companies like Schleuniger or Komax, where harness boards are moved from station to station along a line of human operators.
Each operator is responsible for routing a small number of wires. Once they finish their task, they press a button to signal that their section is complete. When all operators on the line have finished, the machine moves the board to the next station for further assembly.
For simpler harnesses, some aspects of wire production can be automated, much like cable assembly. However, for complex harnesses, achieving precise wire lengths is challenging, and mistakes can be costly. Typically, the wires are cut, laid out on the board, and then manually trimmed to the correct length, stripped, crimped, and plugged.
Even if automating individual wire production were feasible, a large workforce would be required to produce a high volume of wire harnesses quickly to justify the cost of a CST machine. Otherwise, it would be underutilized, waiting for the board layout process to catch up.
CABLE ASSEMBLY VS. WIRE HARNESS MANUFACTURERS
When choosing between cable assembly and wire harness manufacturers, it’s important to understand the distinct qualities you’ll need from each supplier. A suitable cable assembly manufacturer will have the right tooling and expertise for your specific needs and applications.
In contrast, the most successful wire harness manufacturers operate highly specialized facilities and often have access to a large workforce. Given that the wire harness manufacturing process requires extensive space and labor, many facilities that focus on wire harnesses do not produce cable assemblies. While some cable assembly suppliers can efficiently produce simple wire harnesses, they may face challenges when handling more complex harnesses.
LOOKING FOR A CUSTOM CABLE ASSEMBLY SOLUTION?
If you need a manufacturer for custom cable assemblies, it's crucial to partner with a team that has the expertise to produce cables tailored to your specific application, along with the in-house capabilities to meet your exact requirements.
Reach out to us and let us know what you're looking for. If your project involves something outside our scope (like a complex wire harness), we’ll be upfront about it. If you're still in the design phase, we'd be happy to discuss your needs, specs, and ideas.
Hongkong Suntex Electronic Co., Ltd.
