Cable Harnesses – Insulators, Connectors, And Terminals – Miracle Electronics

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When youre looking to protect your wires and
cables against environmental conditions like
moisture, temperature, and friction, youll need
to install cable harnesses in your application.
Depending upon the intended environment, there
are multiple types of cable harnesses available
to choose from.
You may opt for standard readily available
harnesses, or have your harnesses customized by
proficient cable harness manufacturers in
India. When youre planning to have your cable
harnesses customized, you may either tell the
manufacturer all about your requirements, or sit
with them to design your specialized assemblies.
If you choose the latter, you need to first have
a basic understanding about the product, before
you can sit down to decide on what you want.
Considering this, well let you know about the
three main components that comprise a cable
harness, which are insulators, connectors, and
terminals. Insulator types The cables or the
insulation that covers the wires can be of two
types, depending upon the kind of environment or
application the harnesses are to be used in. they
could either be thermoplastics or thermosets.
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• Thermoplastics are the materials that soften or
  melt when exposed to a sufficiently high
  temperature, but also easily harden when cooled.
  They can be repeatedly softened and hardened by
  heating and cooling, without affecting the
  performance of the material. This quality enables
  recycling of the components, which also proves
  to be economical. Some common thermoplastic
  insulations include PE, PVC, PVDF, ECTFE, and
  nylon.
• Thermosets are the materials that dont soften
  even at high temperatures, but theyre rubbery
  and retain their properties at all times.
  However, once moulded or cast, these materials
  cannot be reshaped, because the moulding results
  in a permanent chemical change within the
  materials structure. Some common thermoset
  insulations include CPE, EPR, and XLPE.
• Connector types
• Connectors are the electromechanical devices used
  to form a continuous electrical signal between
  the cable harness and power source. Basically,
  connectors consist of male plugs and female
  jacks that are joint together to relay an
  electronic signal. Such connectors broadly
  differ in materials, sizes, shapes, and
  dimensions, which can be chosen from or
  customized as per the intended application. The
  mating type, the insulation requirement, the
  power contacts, and the signal contacts are all
  the different factors that determine the kind of
  connector required by the application. When
  selecting a connector, it is also very crucial to
  know the wire size, circuit size, circuit
  density, operating voltage, current rating, and
  other such important numbers.
• Terminal types
• Terminals are the electromechanical devices that
  terminates a conductor to a fixed post, stud,
  chassis, etc. in order to establish a connection.
  Available in a variety of designs, shapes, and
  sizes, terminals may be crimped, soldered,
  press-fitted, or wire- wrapped. They are
  available in ring, spade, hook, bullet, butt, and
  flagged forms. The type of terminals to be used
  can depend on the requirements of the intended
  application. The terminals could be insulated or
  non-insulated. Insulated terminals are better
  used in harsh environmental conditions to protect
  the device and components from moisture and
  temperature extremes. If no such protection is
  required, non-insulated terminals are an
  economical choice.
• Determining the type of insulator, connector, and
  terminal is of prime importance to come up with
  the best performing cable harness. They harness
  should be very carefully designed while keeping
  the specific application needs and environmental

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conditions in mind. The correct materials, sizes,
and shapes are vital to ensure that the
harnesses are properly placed and appropriately
routed, while being completely protected.
Professional cable harness manufacturers in India
like Miracle Electronics can take care of every
such aspect that affects the quality of the end
product , so as to come up with a harness thatll
extend the life of the wires, without requiring
early replacements or repairs. Its thus always
better to partner with a professional for even
the smallest electrical or electronic build.