Customized Wire Harnesses – The Materials To Choose - Miracle Electronics

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Customized Wire Harnesses The Materials To
Choose Miracle Electronics People prefer
everything to be customized as per their
preferences today, so much so that professional
companies want to customize their wires that
need to be installed into their applications. If
you are one such company looking to order a
customized wire or wire harness, you should get
in touch with professional wire harness
manufacturers from India, one like Miracle
Electronics, who have enough experience of
manufacturing all kinds of simple and
complicated wire harnesses for different
industrial sectors.
And, when you do so, you should also be sure on
your part, about what all you want to include in
your product. There are various components that
are teamed up to make a wire harness and you
must be sure about the choice of each one of
these. And, in order to make the right choice,
you must first understand all the environmental
conditions and other factors that your wire
harness or application will be subject to. Will
the environment be highly humid or extremely hot?
Will the
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• product have to bear excessive pressure or
  abrasion? After you understand the requirements
  completely, you will be in a better position to
  make the right choice. Here is a complete list
  of all the components that you need to consider
  while planning up a customized wire harness and
  each one comes with a list of the various
  options available.
• Conductor
• Conductor is the very important material in a
  wire harness that allows the flow of an
  electrical current in one or more directions
  within the wire. The most common material used is
  copper, but there are many other options like
  nickel, silver, tin, and aluminum too.
• Copper has low thermal expansion and high
  conductivity, available at a very reasonable
  price.
• Nickel is very reliable in every kind of
  condition like low temperature, high
  temperature, high humidity, and acidic.
• Silver is very conductive, and very expensive
  too.
• Tin is easily solderable, but has moderate
  conducting ability

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• Aluminum is very light in weight and cheap, but
  it is the least conductive.
• Stranding
• Just as much as choosing the wire material is
  important, equally important is choosing the
  type in which the wires need to be stranded.
• Bunching The strands are twisted together with
  no arrangement.
• Concentric stranding A central wire is
  surrounded by a layer of wires, which is hen
  surrounded by another layer of wires, twisting
  in the opposite direction.
• Unilay stranding The strands are arranged in a
  circular pattern, with different layers twisted
  in the same direction.
• Rope lay stranding A concentric arrangement,
  with groups of wires laid one over the other to
  form a rope type figure.

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Insulation and jacketing Insulation is a covering
that protects the conductor against any kind of
current leakage. Also, any incoming physical
abuse can be prevented with the help of
insulation. Over the insulation comes another
protective layer of jacketing, which is designed
to protect the wires against chemicals, moisture,
and mechanical damage. The most popular
insulating and jacketing materials used include

• PVC The material can perform effectively at
  temperatures between -20 to 105C, and has good
  fire resistance, chemical resistance, UV
  resistance, durability, and flexibility.
• Polyethylene and polyurethane Both these
  materials can perform effectively at
  temperatures between -60 and 80C, and have good
  chemical resistance, UV resistance, durability,
  and flexibility but are very poorly resistant to
  fire.
• Thermoplastic rubber or elastomer The material
  can perform effectively at temperatures between
  -40 and 90
• C, and is surprisingly good in terms of fire
  resistance, chemical resistance, UV resistance, d
  urability, and
• flexibility.

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• Shielding
• If your wires are being used for
  telecommunication applications, or when they
  have to be used in close proximity to a large
  number of additional cables, you need to keep
  them protected against electromagnetic
  interference and this is why you will need to
  consider offering an additional layer of
  shielding.
• Braid shielding offers moderate flexibility with
  the material being interwoven into a tubular
  structure or rectangular cross-section. It is
  the strongest and most reliable type of
  shielding. Materials like steel, aluminum, and
  copper are used.
• Spiral shielding offers highest flexibility with
  lowest weight. Steel is most popularly used.
• Foil shielding looks like a foil gum wrapper, and
  is constructed with tape being either Mylar or
  aluminum. This type of shielding offers
  comparatively better resistance to
  electromagnetic interference and noise.
• Fillers
• Fillers may be used to strengthen the cable by
  supporting the outer layers, and increasing the
  flexibility of the construction, while also
  offering a rounder and smoother construction. The
  most popularly used fillers include

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• Polyethylene, which is a lightweight material
  that can be easily moulded, making it ideal for
  longer wires.
• Cotton, which is a low cost solution as the
  durability is comparatively lesser, but the
  flexibility offered is good.
• Steel, which is highly strong and durable, and
  can be tied off at either end of a harness, to
  transfer any force the wire encounters, away
  from the conductors, and onto a housing inside
  the harness.
• Foam, which can be made out of a variety of
  materials, effective for filling in small spaces
  between wires, and retaining the wire harness
  shape.
• Using the above knowledge, you can make the right
  choices for your particular wire harness,
  depending upon the various requirements you need
  to fulfill. So, make your decisions, and get in
  touch with one of the best wire harness
  manufacturers from India to discuss, and have
  your harnesses made.
• For more Information https//www.miracle.net.in/