Served as a crucial element of electrical systems, a terminal wire harness has widespread use in auto, industrial machinery and consumer electronic applications. The lifespan, safety and efficiency of electrical systems can be ensured by the matched terminal wire harness. However, it is a bit difficult to pick out the fit one since there are various kinds of harnesses available on the market. A detailed selection guide is offered in this blog to help you choose an appropriate terminal wire harness based on your specific needs.

The Definition of Terminal Wire Harness

Being an assembly of wires or cords bundled together by durable materials and matched with terminals at every end to achieve the enhancement of secure electrical links among various elements. The wiring procedures can be simplified through the organization of various wires into one unit, with which the setup is simplified while also providing greater protection against signal interference, electrical shorts and environmental conditions.

Aspects to Consider If Choosing a Terminal Wire Harness

The selection of the matched terminal wiring harness not only fits wires into a single connector. What’s more, aspects like environment, device, wire gauge and the composition of material are high crucial for the cable selection. Major factors should be taken into consideration to help you make a wise choice.

The Kind of Application

Firstly, the specific device you will apply depends on which type of a terminal wire harness you select. Wire harnesses are required differently by various industries and uses. If a wrong wire cable is chosen, poor performance or even malfunction can be caused.

1. Auto: Terminal wire harnesses built with highly-resistant materials like PVC or XLPE are widely used for auto systems because the durable harnesses are capable of ensuring high exposure to vibration, fluctuated temperatures or other harsh condition.
2. Aerospace: Terminal wire harnesses have capability to endure fluctuated temperatures and high altitudes, which are specifically needed for aerospace uses. Another reason is they are usually made from high-performance materials like PTFE or ETFE.
3. Consumer Electronic Application: The size, flexibility and signal block capability are highly crucial for selecting a matched wire cable because they are required by electronics because of its compactness and capability of decreasing EMI to avoid signal interference.
4. Industrial Device: Terminal wire cable that can withstand harsh environments, such as high heat, wear and tear are high required by industrial machinery in which materials like TPE are usually applied.

Wire Gauge & Current

One of the most essential aspects that decides the matched terminal wire harness lies in the wire gauge, or the diameter of the cables in the harness. The amount of electricity that can be safely carried by the wire harness is decided by the wire gauge, without leading to overheated issue.

1. Low-Gauge Wire: More current can be carried by wires (e.g. lower gauge amounts) with thicker insulation. Also, thicker wires are usually applied in devices that require high electricity like auto starters or industrial motors.
2. High-Gauge Wire: This type of wire is thinner and also has higher gauge amounts, which is perfectly fit for applications with lower-electricity like control systems and consumer electronic applications.

The Kind of Terminal

Terminals work as the connection bridges between the terminal wire harness and other elements. The selection of the matched terminal kind plays a crucial role in guaranteeing a steady and fastened link.

1. Ring Terminal: This type of terminal is widely employed in auto and industrial uses. Designed with a circular shape, they are allowed to slide over a stud or bolt, which creates a steady and smooth connection.
2. Spade Terminal: Designed with a forked form, these terminals are easily connected and disconnected with no complete removal of the bolt or screw, which are perfectly fit for electrical systems that frequent maintenance is needed.
3. Bullet Connector: Providing a swift disconnection, this type pf cylindrical connector is widely applied in the wiring systems of auto and motorcycle because of its simple and easy application.
4. Butt Connector: Two wires are jointed end-to-end with these connectors and they are fit for devices where various wires are required for being spliced together.

The application is decided by the benefits of each type of a terminal. If high durability and long-time connections are needed for your project, it is highly advisable that ring or spade terminals are selected.

The Composition of Material

Durability, system performance and safety are highly decided by the material composition pf the wires and terminals. The following breakdown of the most universal materials applied for wire harnesses and terminals are shown.

1. Copper Wire: Because of the excellent conductivity, copper is mostly used for conductors. It has high reliability for most devices, but XLPE-insulated copper wires are more popular in heated conditions.
2. Aluminum Wire: Aluminum is a material that is lighter and cheaper than copper. This kind of material is applied in uses where weight is crucial. On the other hand, aluminum has lower conductivity than copper and insulations that are easier to corrode as time goes by, which is relatively not fit for high-performance or harsh conditions.
3. Nickel-Plated Terminal: With excellent resistance to corrosion, this type of terminal is widely employed for applicable environments that have high exposure to humidity or chemical substances.
4. Gold-Plated Terminal: Providing great conductivity, gold-plated terminals are widely applied in high-precision electrical applications or data transfer systems where the integration of signal matters.

Environmental Factors

The applicable environment of a terminal wire harness plays a crucial role in the selection process. Temperature, humidity and exposure to other conditions should be highly considered:

1. Temperature: It is highly advisable to use wire harnesses built with heat-resistance materials like PTFE in high-heat devices, such as auto machines. With these materials, the wire harness is capable of withstanding high temperatures.
2. Humidity & Corrosion: A water and corrosion-resistant terminal wire terminal plays an essential role for electrical systems that have high exposure to humidity, such as outdoor uses.
3. Vibration: Wire harnesses built with flexible materials and fastened terminals are widely used for systems that have exposure to vibration. These systems include heavy machines or transportation devices, so as to avoid wires to loose.
4. Chemicals: Terminal harness insulated with chemical-resistant materials are better fit for industrial conditions where chemical substances are applied.

Safety Compliance

Some safety compliances may need to be fit for the wire harness, relying on the industry. Examples include:

1. SAE safety standard should be met for the wire harnesses in auto uses. FAA guidelines need to be strictly abided when designing aerospace wire harnesses to confirm the performance and safety standard are fit. An UL or CE certified wire harness may be required for consumer electronic devices.

Length & Custom

The simplicity and easiness of setup, and the performance in your special device can be greatly impacted by the choices (for terminal wire harnesses) of length and customization. Several factors are included:

1. Length: Terminal wire harnesses must have enough length to cover the distance between elements with no need to put much pressure on the wires. However, harnesses with excessive length can generate clutter and enhance the hazard of disruption.
2. Customization: A custom terminal wire harness may be needed for meeting specific requirements in some typical cases like specific kinds of connectors. Here, delightfire provides customizable choices to make sure your wire harness matched greatly within electrical system.

Conclusion

The selection of a matched terminal wire harness plays crucial roles for the fitness of your electrical system, and it also helps improve the great and smooth performance. Factors like type, wire gauge and terminal type should be carefully considered. The efficient, safe and reliable wire harness can be ensured through the careful evaluation of each component, no matter the use.

A terminal wire harness should be chosen to be fit for your special demands, which enables the successful setup of your electrical system to achieve the enhancement of performance, lifespan extension, and safety increasement.