Harness Draft - Product Knowledge - 16th Dec 2016

Harness Design
Ashok Bachu
1 © 2016 WIPRO LTD | WWW.WIPRO.COM | CONFIDENTIAL

Topics
What is Harness
Advantages
Applications
Fundamentals
Components used in Harness

6 Electric Power Connectors
7 Terminals
8 Wires/Cables
9 Mechanical Supports
10 Types of circuits
6 Steps involved in Harness Design
7 Design Considerations
8 Manufacturing

What is Harness
Harnessthe
A wiring harness is an organized set of wires, terminals and connectors that run throughout BOM
entireExtraction
system thereby performing a critical
role in “connecting” a variety of components.
Features:-
 Harnesses may have several hundred wires and components
 A wiring harness may include single wires, coaxial cables, shielded groupings, fiber optics, air tubing, etc.
 It is also known as cable assembly, wiring assembly or wiring loom, is an assembly of cables or wires which transmit signals or electrical
power

Advantages
 It provides one connection point for multiple wiring configurations. Harness BOM Extraction
 Harness model reduces the allowable variation of wire from 40% to 10%.
 BOM helps the shop floor engineer to overcome the trial and errors methods of routing
 Harness assembly helps to reduce maintenance cost and time
 These are used as a direction map for connecting the wires with electronic devices.
 It is used to calculate the exact wire length required for wiring for the system. And thus it saves the Material cost of Wire.
 Advantage over loose wire and cables.
 Installation time is decreased and process can be easily standardized.
 Harnesses are designed to perform under extreme conditions with uninterrupted services and to sustain heavy loads at the same
time.

Applications
 Aerospace Harness BOM Extraction
 Automotive
 Rail
 Heavy Industries &
 Consumer white Goods Etc., RAIL
Consumer White
Goods
AUTOMOTIVE AEROSPACE HEAVY INDUSTRIES

Fundamentals of Electricity
Basics Definitions:- Harness BOM Extraction
Current:
Current is flow of charged particles through conducting medium. Current is produced when the electrons move from one place to
another. Direction of current produced is opposite to the movement of electrons.
Voltage:
Voltage is the amount of potential energy between two points on the circuit, in which one point has more charge than another
Resistance:
Resistance is the opposition that a substance offers to the flow of electric current.
The circuit with the higher resistance will allow less charge to flow, meaning the circuit with higher resistance has less current flowing through it.
By Ohm’s law I =V/R

Fundamentals of Electricity (Contd.,)
Type of Current:- Harness BOM Extraction

Current is in the form of two types.
Direct Current Current(DC):

In the Direct electric current flowing in one direction only.The current
is produced by means rotation of coil around the steady magnetism.
It is the current of constant magnitude
Alternate Current Current(AC):

Alternating current (AC), is an electric current in which the flow of electric charge periodically reverses direction,
The current is produced by means of Rotating magnet along the wire.The usual waveform of alternating current in most electric
power circuits is a sine wave

Basic Electrical Devices Harness BOM Extraction

Capacitor:
Capacitor is an electronic component that stores electric charge.
The capacitor is made of 2 close conductors (usually plates) that
are separated by a dielectric material. The plates accumulate electric
charge when connected to power source. Capacitor
Inductor:
An inductor is a passive electronic component that stores energy in the form of a magnetic field.
In its simplest form, an inductor consists of a wire loop or coil. The inductance is directly
proportional to the number of turns in the coil
Inductor
Diode:
A diode is an electrical device allowing current to move through it in one direction by blocking current in the opposite direction
Diode

Invertor:
Harness BOM Extraction
It is an electronic device or circuitry that changes direct current (DC) to alternating current (AC).
Inverters are used to convert DC electricity from sources like solar panels, batteries or fuel cells to AC electricity
Invertor
Rectifier:
A rectifier is an electrical device that converts alternating current (AC) to direct current (DC)
This involves a device that only allows one-way flow of electrons.
Circuit with Diode Arrangement

Rectifier with flow of current in one direction
Transformer:
Harness BOM Extraction
A transformer is an electrical device that transfers electrical energy between two or more circuits through electromagnetic induction.
Electromagnetic induction produces an electromotive force within a conductor which is exposed to time varying magnetic fields. Transformers are
used to increase or decrease the alternating voltages in electric power applications.
A varying current in the transformer's primary winding creates a varying magnetic flux in the transformer core and a varying field impinging on the
transformer's secondary winding. This varying magnetic field at the secondary winding induces a varying electromotive force (EMF) or voltage in th
secondary winding due to electromagnetic induction.
Transformer
Components used in Harness
There are different types of components used in Harnesses according to their applications.
Basically components can be classified as
 Active
 Passive
 Electro mechanical
Active components:
Components which are rely on a source of energy and usually can inject power into a circuit are called as Active Components.
Below are the categories
 Semiconductors
 Diodes
 Transistors
 Display technologies
 LED
 LCD
 Flap indicator

 Power sources
Transistors/Semiconductors/LEDS Battery
 Battery
 Power supply
Components used in Harness (Contd.,)
Passive components :
Components which can't produce Power into the circuit but they may control/Maintain voltage or current in the circuit Semiconductors
are called as Passive Components. Below are the categories
 Resistor
 Capacitors
 Magnetic Devices
 Inductor
 Transformer

 Transducers, Sensors, Detectors
 Audio
 Motion Sensor
 Accelerometer Audio, Motion sensors
 Thermistor

Components used in Harness (Contd.,)
Electro mechanical :
Components which can carry out electrical operations by using moving parts or by using electrical connections are called as Electro mechanical
components. Below are the categories
 Terminals
 Connectors
 Switches
 Thermostat
 Relay
 Reed switch
 Limit switch Power Cord
 Cable Assemblies
Switches/Resonators/Crystals
 Power cord
 Piezoelectric devices, Crystals, Resonators
 Protection devices
 Fuse
 Circuit breakers
 Lightning Arrester
 Spark gap

 Mechanical Accessories
Protection Devices
 Heat sink Connectors/Terminals
15  Fan © 2016 WIPRO LTD | WWW.WIPRO.COM | CONFIDENTIAL
Electric Power Connectors
Properties of Electrical Connectors:-
Electrical connectors are characterized by different types of Properties which are mentioned below
Pin Out
 Physical Construction
 Size
 Contact Resistance
 Insulation between Pins
 Resistance to Vibration
 Resistance to Entry of Liquids
 Resistance to Pressure
 Reliability
 Lifetime
 Ease of Connecting and Disconnecting
Basically Electrical Connectors classified based on the Voltage carried by them and they are three types.
1. Light-duty - Voltage Range( 0 - 250 V)
2. Medium-duty - Voltage Range( 250 - 1000 V)
3. Heavy duty – Voltage Range(Above 1KV )

Electric Power Connectors (Contd.,)
In addition to the three general categories of power connectors, there are numerous individual connectors that fall under each heading. Some of
these variants include:
AC Connectors
AC power connectors are mainly used to connect equipment to a wall outlet in order to power the device. Of the types of AC connectors, power
plugs are for standard size devices while industrial AC power plugs are for larger industrial applications.

DC Connectors
Unlike AC connectors, DC connectors are not standardized. A DC plug, a variant of a DC connector, primarily supplies smaller electronic devices
with power. Because there are different standards of DC plugs, it’s important not to accidently use incompatible variants.

Wire Connectors
The purpose of a wire connector is to bring two or more wires together at a common point of connection. Lugs, crimps, set screws, and split-bolt
types are all examples of this variant.

AC Connectors DC Connectors Wire Connectors

Electric Power Connectors (Contd.,)
Blade Connectors
Blade connectors feature a one wire connection—the blade connector is inserted into a blade receptacle and when the blade connector’s wire
makes contact with the receptor’s wire a connection is made.

Plug and Socket Connectors
Plug and socket connectors consist of a male and female component which fit together snugly. A plug, the male component, is comprised of many
pins and prongs, which when inserted into the female socket, securely latch on to corresponding contacts.

Insulation-Piercing Connectors
Insulation piercing connectors are useful because they don’t require uncovered wires. Instead, a fully covered wire is inserted into the connector,
and a small device inside the opening removes the wire’s covering as the wire slides into place. Then, the uncovered tip of the wire makes contact
with the receptor, and electricity can be transmitted.
Plug and Socket

Insulation-Piercing Connectors Blade Connectors
Connectors

Terminals
A Terminal is the point at which a conductor from an electrical component, device or network comes to an end and provides a point of
connection to external circuits. A terminal may simply be the end of a wire or it may be fitted with a connector or fastener. In network
analysis, terminal means a point at which connections can be made to a network in theory and does not necessarily refer to any real
physical object
Type of Terminals
 Splices
 Cups
 Hooks
 Solder Lugs
 Tongue Crimp terminals (ring terminals)
 Test probes (pogo terminals)
 Clips
 Screw Terminals
 Tab terminals (quick-connect, quick-disconnect)
 Wire Nuts

Splices Cups Tab terminals Wire Nuts Solder Lugs
Hooks
Tongue Crimp Test probes Clips Screw Terminals

terminals

Wires/Cables
Wire:
A single metallic conductor of solid, stranded, or tinsel construction, designed to carry current in an electrical circuit. It may be bare or
insulated, but does not have a metallic covering or shield
Wires are used to bear mechanical loads or electricity and telecommunications signals.
Wire is commonly formed by drawing the metal through a hole in a die or draw plate.
Different colour codes are used for different purposes and application according their own Organisation standards
Cable:
An electrical cable is an electrical unit that consists of a multiple number of independent conductive wires.
The wires within the cable may be solid core, stranded, braided, or a combination of several of these.

Mechanical Supports
Mechanical Supports:-
Supports are used to hold the harness in rigid manner. These are used to fix the wires/Components at required locations as an assembly.
Some of the supports used in Harness are as below

 Cable ties
 Clamps
 Clips
 Glands
Gland
Clip Holder
Gluing Pad Wire Tie

Types of circuits

Color Coding of Wires
Different Cable Classes:
Different Classes of the Cables and their respective color Codes:

Steps involved in Harness Design
Gathering
Specifications
Gathering
Specifications
Creation of Block/Circuit
Diagram
Development of
Schematic/
Development of
Harness Drawing
Schematic/
Harness Drawing
3D Harness Modelling
Flattening/Form
Drawing Creation
Testing And
Installation

Steps involved in Harness Design (Contd.,)
Gathering Specifications:
The process of Harness design begins with the specification, which states the functionality that the finished design must provide, but
does not indicate how it is to be achieved.
 Type of Signals (Ex:- Analogue, Digital)
 Input Power (Ex:- 220V, 5A)
 Consumption Power ( Ex:- 5 Watts)
 Size
 Weight
 Moisture resistance (Ex:- Ingress Protection)
 Temperature range (Ex:- -25 Degrees to +100 Degrees)
 Thermal output
 Vibration Tolerance
 Tightening Specifications (Ex:- 1.5 N-M)
 Tests to be passed ( Ex:- Circuit Passing Test, Voltage Test )

Creation of Block/Circuit Diagram:
A block diagram is a diagram of a system in which the principal parts or functions are represented by blocks
connected by lines that show the relationships of the blocks
Block diagrams are typically used for higher level, less detailed descriptions that are intended to clarify
overall concepts without concern for the details of implementation.
In some of the cases, Circuit diagrams will also prepared directly. Circuit diagrams are pictures with symbols.
Simple components often had symbols intended to represent some feature of the physical construction of
the device
Circuit Diagram Block Diagram

Development of Schematic/Harness Drawing:
Schematic is a graphical representation of an electrical circuit. A pictorial circuit diagram uses simple images
of components, while a schematic diagram shows the components and interconnections of the circuit using
standardized symbolic representations. The presentation of the interconnections between circuit
components in the schematic diagram does not necessarily correspond to the physical arrangements in the
finished device
Harness Diagram is developed from the Schematic. A Schematic can be understand by Electrical Engineers
only whereas Harness Diagram can be read by Mechanical engineers also.
28 Schematic Harness Drawing

© 2016 WIPRO LTD | WWW.WIPRO.COM | CONFIDENTIAL
Harness Modelling:
Harness Modelling involves preparation of 3D Harness by taking the Harness Diagram as input in the CAD
Tools like CATIA, CREO Cabling,Solid works etc.,
It involves
 Defining the required connectors and connection points.
 Geometric Bundle creation.
 Linking the various connection points and geometric bundles which will behave as a space reservation
for the wiring.
.
3D Harness Model
Flattening & Form Board Drawing Creation:
Harness flattening involves creation of flattened Model from the Created 3D harness Model. Form Board
drawing can be generated from the flattened Model. Flattening and form board drawing creation can be
done in different tools like CATIA, CREO Cabling etc.,
Benefits
 The length tolerance function allows the user to add extra length on segments, to take into account
manufacturing constraints directly in the flattening data. This ensures the right quality of length to each
part of the harness, to secure harness final assembly between the products
Flattening Model Form Board Drawing

Testing and Installation:
After creation of Flattening drawings, Circuits will be tested as per the requirement. Mainly Power Continuation will be
checked with simple techniques. EMC Testing is another important test to avoid the Electro Magnetic Compatibility.
Once the Circuit passed all the tests, then it will be installed into the product as per the installation drawings.
During installation, All support will be arrange as per the specifications to hold the wires with required slag.
Drawings plays a key role in installation period to install the cable assemblies into the product
Manual testing Computer based Testing

Installation
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Design Considerations
Electromagnetic Compatibility
EMC is concerned with the unintentional generation, propagation and reception of electromagnetic energy which may
cause unwanted effects such as electromagnetic interference (EMI) or even physical damage in operational equipment.
The goal of EMC is the correct operation of different equipment in a common electromagnetic environment.
EMC Guidelines
Require connector segregation, at best one connector per main class (1, 2, 3, 4 or 5). If this is not possible, separate the
classes within the connector.
The only classes that can be connected within the same connector are: 1&2, 3&4

 Different classes of the cables should be routed with appropriate distance as specified in the below table, in certain
cases these distances can be replaced by placing one or two separators. While placing two separators the separation
distance between these two separators should be 10 mm.
In the above table Minimum separation distances of the cable assemblies are given in centimeters
For Example: As per the above table the A minimum distance of 8 cm is recommended between classes 1A and 3.

An Example for the arrangement of different classes of cables
Here the distance between 4A and 4B is less than 8 cm, so separator is placed.

 The recommended distance relates to the distance between outer Faces of the cable bundles, not the
distance between their centers.
The height of separator must be at least equal to the diameter of the larger of the bundles to be separated

 The shortest possible cable paths shall be used.
 Cables of same class can be grouped together to form a multi-branch cable.

In multi branch cables at the point of converging, the diameter of the cable increases and at the point diverge
the diameter of the cable decreases
Converging Diverging

 The inner radius of bending of the cables shall be at least 5 to 8 times the diameter for a single or multi-
core cable
Diameter
Bend Radius

Grounding
All electrically neutral, metal or non-metal conductive equipment that could come into contact with nearby active electrical parts, due
to a fault or damage, and that are accessible to the touch must be grounded.
Example: cable trays.
The metal contact surfaces with the grounding braids or cables must:
 be covered with a paint mask or be brushed top remove any traces of surface protection (the metal must be bare)
 be pickled and degreased to remove any greasy substances
 be coated with contractual HPG grease
 finally, be cleared of any excess grease after tightening.
These rules must be indicated in a note on the wiring installation drawings.
Furthermore, do not make more than 2 grounding connections per stud

as shown in the figure.

Shielding
Shielding:
 The shielding must be made done from tinned copper braided shield around the conductors.
 Only network cables are to be systematically shielded.
 Other cables may be shielded if agreed by the supplier, the systems engineer and the EMC engineer.
.
Poor solution for Junction Box Good solution for Junction Box

Manufacturing of Wires
1. Wire Drawing-
Preaperation of
wires 1 2 3
1 2 3
2. Cutting Stripping
& Crimping- Attaching
components to Wires
4
3. Preparation of
circuits and
Subassemblies
4. Assembly 5
5. Testing and
installation

Thank You

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Harness Design

1 © 2016 WIPRO LTD | WWW.WIPRO.COM | CONFIDENTIAL

Components used in Harness

4 © 2016 WIPRO LTD | WWW.WIPRO.COM | CONFIDENTIAL

5 © 2016 WIPRO LTD | WWW.WIPRO.COM | CONFIDENTIAL

6 © 2016 WIPRO LTD | WWW.WIPRO.COM | CONFIDENTIAL

 Aerospace Harness BOM Extraction

AUTOMOTIVE AEROSPACE HEAVY INDUSTRIES

8 © 2016 WIPRO LTD | WWW.WIPRO.COM | CONFIDENTIAL

Type of Current:- Harness BOM Extraction

Direct Current Current(DC):

Alternate Current Current(AC):

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Basic Electrical Devices Harness BOM Extraction

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Circuit with Diode Arrangement

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16 © 2016 WIPRO LTD | WWW.WIPRO.COM | CONFIDENTIAL

AC Connectors DC Connectors Wire Connectors

17 © 2016 WIPRO LTD | WWW.WIPRO.COM | CONFIDENTIAL

Plug and Socket

18 © 2016 WIPRO LTD | WWW.WIPRO.COM | CONFIDENTIAL

19 © 2016 WIPRO LTD | WWW.WIPRO.COM | CONFIDENTIAL

Tongue Crimp Test probes Clips Screw Terminals

20 © 2016 WIPRO LTD | WWW.WIPRO.COM | CONFIDENTIAL

21 © 2016 WIPRO LTD | WWW.WIPRO.COM | CONFIDENTIAL

22 © 2016 WIPRO LTD | WWW.WIPRO.COM | CONFIDENTIAL

23 © 2016 WIPRO LTD | WWW.WIPRO.COM | CONFIDENTIAL

24 © 2016 WIPRO LTD | WWW.WIPRO.COM | CONFIDENTIAL

25 © 2016 WIPRO LTD | WWW.WIPRO.COM | CONFIDENTIAL

 Type of Signals (Ex:- Analogue, Digital)

 Input Power (Ex:- 220V, 5A)

 Consumption Power ( Ex:- 5 Watts)

 Moisture resistance (Ex:- Ingress Protection)

 Temperature range (Ex:- -25 Degrees to +100 Degrees)

 Tightening Specifications (Ex:- 1.5 N-M)

 Tests to be passed ( Ex:- Circuit Passing Test, Voltage Test )

Circuit Diagram Block Diagram

28 Schematic Harness Drawing

Flattening Model Form Board Drawing

Manual testing Computer based Testing

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34 © 2016 WIPRO LTD | WWW.WIPRO.COM | CONFIDENTIAL

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36 © 2016 WIPRO LTD | WWW.WIPRO.COM | CONFIDENTIAL

 The shortest possible cable paths shall be used.

 Cables of same class can be grouped together to form a multi-branch cable.

37 © 2016 WIPRO LTD | WWW.WIPRO.COM | CONFIDENTIAL

38 © 2016 WIPRO LTD | WWW.WIPRO.COM | CONFIDENTIAL

Furthermore, do not make more than 2 grounding connections per stud

39 © 2016 WIPRO LTD | WWW.WIPRO.COM | CONFIDENTIAL

40 © 2016 WIPRO LTD | WWW.WIPRO.COM | CONFIDENTIAL

41 © 2016 WIPRO LTD | WWW.WIPRO.COM | CONFIDENTIAL

42 © 2016 WIPRO LTD | WWW.WIPRO.COM | CONFIDENTIAL

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