Product Knowledge

Connectors

Terminals

Wire Harness

Automotive Connectors: Car, Truck, Bus, & Off-Road.

JDE Automotive is a leading supplier to the automotive industry. Innovating together, we work side-by-side with customers in virtually every industry to create answers to the connectivity challenges of tomorrow. JDE provides quality electrical and electronic interconnection products for automotive, on- and off-highway, and hybrid and electric vehicles to electrically and mechanically join wires and cables, printed circuit boards, integrated circuit packages, and batteries. Our automotive connectors are built to withstand tough conditions and suit the needs of varying industries.Automotive Connectors: Car, Truck, Bus, & Off-Road.

The Role Of Terminals

Automotive terminal connectors are pivotal components in the vehicular electrical ecosystem, designed to ensure reliable and effective connectivity among various electrical circuits. Serving as a bridge for electrical currents, these connectors facilitate the necessary flow of power and data, which is critical for the vehicle's operational integrity and user safety.

Functionality

Their core function lies in enabling secure connections between wires, sensors, and devices, helping to transmit signals and supply power throughout the automobile. They must withstand the vibrations, temperature fluctuations, and harsh conditions typical of automotive environments while preventing energy loss and maintaining signal fidelity.

Applications

The use of terminal connectors spans across the entire breadth of a vehicle’s systems. From instrumental panel functions and engine management systems to lighting, climate control, and infotainment systems, these connectors are integral. They also play a key role in the safety features of a vehicle, including airbag deployment circuits and traction control systems, underlining their essential contribution to vehicular safety and functionality.

Materials

Terminal connectors are generally fashioned from high-conductivity metals such as copper, brass, or aluminum, often plated with materials like tin or nickel to boost corrosion resistance and enhance connectivity. Some are encased in durable plastics or rubber to provide additional protection against moisture, chemicals, and temperature extremes. These materials are meticulously chosen to not only conduct electricity efficiently but also to endure the demands of their specific automotive applications.

Overall, automotive terminal connectors are fundamental to the smooth operation of modern vehicles, with their functionality, applications, and materials carefully orchestrated to meet the rigorous demands of automotive engineering.

What is a Wire Harness?

A wire harness, often referred to as a cable harness or wiring assembly, is a systematic and integrated arrangement of cables within an insulated material. The purpose of the assembly is to transmit signal or electrical power. Cables are bound together with straps, cable ties, cable lacing, sleeves, electrical tape, conduit, or a combination thereof. The wire harness simplifies the connection to larger components by integrating the wiring into a single unit for “drop-in” installation.

Wire Harnesses vs. Cable Assemblies

Wire harnesses are often confused with cable assemblies however, the two are quite different. The main difference is that a cable assembly normally has only two ends, whereas a wire harness contains multiple breakouts (ends) that run in many different directions with multiple terminations on each breakout.

Wire assemblies are most commonly used in the transportation industry, including automobiles, buses, trucks, and planes. Construction machinery, industrial equipment, electronics and white goods (household appliances) will also be constructed using wire harnesses.

Wire Harness Assembly Benefits

Decreased installation time: Many vehicles require miles of wiring in order to operate. A wire harness assembly process greatly simplifies the manufacturing of these vehicles by integrating all the wires and cables needed into a single apparatus. The installation then becomes a simple matter of “dropping in” the harness, rather than running all of the wires individually.

Security and safety: When wires and cables are bound within a single harness, the individual components are more secure against the adverse effects of vibrations, abrasions and moisture. Space is optimized and the risk of an electrical short is reduced because the wires have been constructed into a non-flexing bundle. The risk of electrical fire is also reduced when the wires are bound within a flame-retardant sleeve.

Wire Harness Design and Pre-Production

A wire harness process is designed based on the geometric and electrical requirements of the equipment it is to be installed in. Once the initial design is established, a schematic is used to create the manufacturing paperwork and the assembly board for the harness. The assembly board, also called a pin board, is a full-size diagram of the harness which shows all of the components and their locations. It also serves as the workbench for the harness.

Wire Harness Manufacturing/Assembly Process

The wires needed for the harness are first cut to the desired length and labeled appropriately. Next, the ends of the wires are stripped to expose the uninsulated conductor and fitted with any required terminals or connector housings. The wires and components are then assembled on the pin-board to the desired specification and then bound together.

Why Are Wire Harnesses Assembled Manually?

Wire harness assembly process is one of the few remaining manufacturing processes that is more efficiently done by hand, rather than automation. This is due to the variety of processes that are involved in the assembly. These manual processes include:

Wire Harness Production Process
● Installing terminated wires in various lengths
● Routing wires and cables through sleeves and conduits
● Taping breakouts
● Conducting multiple crimps
● Binding the components with tape, clamps or cable ties

Because of the difficulty involved in automating these processes, manual production continues to be more cost-effective, especially with small batch sizes. This is also why harness production takes longer than other types of cable assemblies. Production can take anywhere from a few days to several weeks. The more complicated the design, the longer production time is required.

However, there are certain portions of pre-production that can benefit from automation. These include:

● Using an automated machine to cut and strip the ends of individual wires
● Crimping terminals on one or both sides of the wire
● Plugging wires pre-fitted with terminals into connector housings
● Soldering wire ends
● Twisting wires

Post Production Wire Testing

The final step of the assembly process is to test the harness for electrical functionality. This testing is done with the aid of a pre-programmed test board. The test board is programmed with the required electrical characteristics and the completed harness is then plugged into the board and checked for faults.

Hopefully, JDE Automotive has answered most of your questions regarding wire harness assemblies. If you are wondering if custom wire harness might be right for you. Look no further, we’ve got the answers you need.

Cable Management

Transform your production facility with JDE's industrial cable management system solutions, proudly featuring products from Murrplastik and icotek. These innovative solutions are meticulously engineered to revolutionize your workspace, offering impeccable cable routing, protection, and organization. Say goodbye to cable chaos and embrace a seamlessly organized environment that not only enhances efficiency but significantly boosts safety standards.

With JDE's solutions, expect more than just organized cables - anticipate enhanced safety measures that safeguard your equipment and personnel. When your cables are properly managed and protected, expensive cable and machinery lasts longer, reducing maintenance costs and downtime. Trust JDE to provide cutting-edge solutions from Murrplastik and icotek, ensuring safety, efficiency, and reliability, while simultaneously extending the life of your valuable industrial assets.