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The role of electrical harnesses in modern vehicle design

Today, electrical harnesses are the basis for the operation of most electronic systems. A disruptive factor that seeks the structural efficiency of these in general.

They are not very visible components in the final product but are fundamental for transmitting the executing signals. They are a set of wires that safely and reliably conduct the electrical impulses of the systems.

What are electrical harnesses?

A set of wires, terminals, connectors, clips, tapes, or other components that carry an electrical signal from one point to another. Their arrangement, type, and size depending on the area or module where they operate.

Its use is expanding more and more, being common in several industrial sectors such as:

  • Automobiles and vans
  • Motorcycles
  • Recreational vehicles
  • Airplanes
  • Boats
  • Household appliances and white goods

Of these sectors, harnesses are most in demand in the field, a sector that catalogs them as follows:

  • Pigtail: Harnesses integrated into the module at one end.
  • Jumpers: Harnesses that go from point to point, characterized by being small and having a maximum of two or three connectors.
  • In-line connections: Designed for multiple connections between modules or other harnesses.
  • In addition, based on functionality, they are classified in the industry as follows:
  • Body Harness: Energizes the main safety components.
  • Instrument Panel Harness: Connected to the Body Harness, handles connections to peripherals.
  • Engine Harness: Energizes powertrain components, injection systems, and temperature sensors.
  • Chassis Harness: Connected to the Engine Harness, connects to the fuel pump, wheel sensors, and rear lighting system.
  • FEM” Harness: Connects to the front lighting system, horn, windshield washer fluid pump, various front sensors, and radiator fan.

In the end, with the above, we can state that electronic evolution has made harnesses a fundamental systemic component—a “simplified vehicle wiring” structure for modern technology.

For example, the cable routing process of modern vehicles would be highly complex if harnesses were not used in addition to the higher incidence of human error, the difficulty of maintenance, and other unfavorable factors.

The importance of electrical harnesses in modern vehicle design

Drawing an analogy between a vehicle and the human body, the microcomputer is the brain; the sensors, the sensory system; the actuators, the moving organs; and the harnesses, the nerves, and blood vessels.

Thus, electrical harnesses provide reliability in supplying the transmission of specific current values to electrical and electronic components, avoiding electromagnetic interference and circuit failures.

The process of designing and installing electrical harnesses

While the initial harness design process may use more or less standard EDA tools, the two-dimensional schematic representation of the harness must ultimately be translated into the three-dimensional structure of the vehicle.

These allow the designer to create wiring harnesses, add connectors, define branches off the main harness, define the routes where each harness will be placed, and check for conflicts between the harness and the rest of the vehicle structure.

After design and assembly, installation is manual, as it is a task that requires motor and rational skills that still need to be automated to date.

Common problems with electrical harnesses and how to solve them

According to the scanner, the harnesses or electrical connectors must be replaced when the component no longer receives the signal it should or when it gives a bad reading.

Some sensors stop working, but there is not always a fault in the sensor, and it may not receive the signal sent by the computer, which prevents it from working correctly.

The future of electrical harness technology

Since the traditional methods of automotive wiring and other sectors are not suitable for upgrading technological functions, the development of electrical harnesses is constantly growing.

The evolution of the sector faces the eternal challenge of automating the process of the entire production chain of these components: design, production, and installation. In addition, using aluminum instead of copper as the transmission medium based on wire coatings makes the harnesses more efficient.

Electrical harnesses must evolve toward more efficient structures when visualizing the vehicle electrification sector. Modern systems tend to be highly electronic, and this requires large-scale signal channeling, as is the case, for example, with electric vehicles.

Intelligent technologies are increasingly invading the world, noticeable in vehicles, homes, and other systems used in today’s society. Therefore, the evolution to sophisticated connectivity that is safe, efficient, and reliable is necessary.

Electrical harness manufacturing services

The wire harness manufacturing industry is overgrowing, yet only some suppliers work to high-quality standards.

This can cause many problems for companies that need quality harnesses manufactured quickly and efficiently. 

AMN Quality Solutions offers the best wire harness manufacturing service for any industry. We have over 30 years of experience and use only the latest technology to get your wiring done right, on time, and with the confidence, we are known for.

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