A wire harness is the exterior covering that protects an inner conductor or bundle of conductors. The wire harness arrangements can be crafted differently to serve different purposes for unique applications. Braiding technology has become a great way to cover wire harnesses, especially in aerospace and other high-reliability industries. The braiding of the wire harness is done by sending a wire harness through a Wire Harness Braiding Machine that comes wrapped with the Polymer coated nylon yarn. Braiding technology is often used when a wire harness assembly requires more durability and protection due to harsh environmental applications.
The over-molding technology is widely used in producing connectors and electrical cables. Over molding of the connector is a method where either injection molding or insert molding is performed to merge connectors and wires as a single piece. It helps manufacturers to produce connectors and cables with improved durability, reliability, and versatility.
Therefore, connectors and cable assemblies can withstand the most demanding environments because of technological advancements and the development of materials for mold compounds. The material selection must be one of the essential specifications of a connector. As a result, Overmolded Cable Connectors are used in almost every industry and application.
Reasons to braid a wire harness
The braiding technology increases the tensile strength and durability of the harness. Wire harnesses protected with a braided technology are designed to last longer by providing tightly bound assemblies, having 100% loading, and significantly reducing wire-to-wire movement, reducing insulation wear and deterioration. Electromagnetic interference (EMI) is a necessary data and signal transmission issue. Braiding provides superior protection from EMI. Typically, copper or tin-plated copper braiding materials are used in this situation.
The Wire Harness Braiding is mainly done to protect the cable from Electromagnetic Interference (EMI) and to increase the cable’s flex life and mechanical strength. Another main reason Wire Harness Braiding is done is to protect the various components of the wire harness from high temperatures. To reduce heat transfer, a fiberglass braiding material is used. Finally, braiding can create a more appealing final product, and the common materials used are polyester or nylon.
Application of a Wire Harness Braiding Machine
The Wire Harness Braiding machines are efficient, productive, and relatively quiet. These machines utilize a vertical configuration to create protective layering for electrical wires. Wire Harness braiding is essential for electrical harnesses, providing a protective layer from chafing, heat, and other wear and tear. Colored braiding is a technique used in automotive wire harness manufacturing that involves wrapping a colored braid around a group of wires. The industries using Wire Harness Braiding Machine include the medical, telecommunication, military, and automotive industry.
Hospitals have specific requirements for their wiring needs. Therefore, they require a Wire Harness Braiding machine that fulfills those requirements. Secondly, the telecommunications industry uses wholesale wiring harness braid machines to produce custom-made cables. In the military, the machine produces cables to power foreign military bases and secure private communications on battlefields. The automotive industry uses this machinery to make wires to suit communication technologies.
Introduction to Overmolded Cable Connectors and their Benefits
An over-molded cable connector is simultaneously created and attached to a cable through injection molding. The Overmolded Cable Connectors can eliminate many disadvantages associated with off-the-shelf, mechanically assembled connectors. Overmolded cable connectors provide three significant benefits, flexibility, reduced costs, and enhanced functionality.
When a connector is designed to meet the exact needs, the unnecessary components and materials are cut off, leading to lower material costs and less time spent producing the cable connector and managing the supply chain. The Overmolded Cable Connectors provide insulation, strain relief, and a better seal, improving moisture and water protection. Hence, over-molded cable connectors can help reach a level of performance compared to off-the-shelf, mechanically assembled connectors.