Cable harnesses are a prime component of countless applications today. In fact, people are opting more and more for custom cable harnesses today to suit their requirements. And, with customization comes the factor of cost. So, how can you have a cable harness designed in a way that it meets your requirements, and the environmental and electrical demands, while staying low on costs? Before we delve into the answer to this question, it is important that we check on the elements that add to the costs of a cable harness.
The environment in which the harness will be used and the expected electric performance are the two elements that decide upon the raw materials to be used for building a cable harness. Generally, a cable harness comprises of a medium for data transmission, connectors, shrink tubes, and labels. Choosing the correct connector and cables can help in reducing the costs of a harness.
Connectors are one of the most important parts of a cable harness as this is the interface that a harness can mate with. It could be a cable-mounted connector, panel-mounted connector, or connector mounted to a board – the type of connector used affects the cost of a harness. If you choose a connector to be installed on automated equipment with the help of terminals, plugs, or contacts crimped on the wires, the resulting cable harness will be comparatively very inexpensive. Conversely, if you choose connectors to be hand soldered onto wires for enhanced performance, the costs would go higher. So, your cable harness costs will depend upon your choice of connectors and their installation. However, these choices will be based on the characteristics of transmission that the cable harness is expected to deal with.
Another important part of a cable harness is the cables used that can increase or decrease the amount of costs involved with a harness. Here again, the choice of cables depends upon certain factors like the environment that the cable harness is to be used in and the signals that will be sent through the harness. Using a UL or CE marked cable harness means that it is certified for quality, which determines the compounds needed to be used as an insulator and the sheath material. Higher certifications mean better materials used, which in turn increases the cost.
Next in line is the cable conductor that needs to be used. Considerations regarding its size, material, and plating are important. It is the service life expected of the harness and the type of signal to be sent through it that decides upon all these aspects of a cable conductor. The smaller the size, the more expensive it will be because of the manufacturing issues related with smaller size. Also, more the number of strands within a conductor, higher the cost will be. However, choosing a small conductor with minimum number of strands is a cost-effective solution.
So, choose from the list of cable harness manufacturers in India wisely, and work closely with them to have open discussions about the best possible solution for your cable harness – one that is cost-effective, meaning that it provides enhanced performance within the least costs. Miracle Electronics is who can help customize your cable harness, and provide you with tested and quality certified products that perform in compliance with environmental requirements.