The custom wire harness assembly pictured here is used for a special military vehicle application.
American Precision Assemblers built this special harness from 16 AWG wire using a combination of equipment, including a KOMAX Gamma 333 wire processing machine, a Stapla ultrasonic welder, a pneumatic crimper, an arbor press, 24 bobbin braiding machines, and a custom harness board with integrated tester. Meeting customer specifications for overall length, breakout length, and orientation, the finished unit measured 60 inches long with 8 individual branches. The part also featured 35 position metal connectors, along with 4 position plastic connectors equipped with a locking device.
To begin this process, we first gathered all appropriate material and tools to carry out the build. We stripped each wire per customer specifications and applied terminals to these wires. We then twisted the wires using a mechanical twister. The terminals were installed into a large connector using guide pins and then fitted into eight separate, smaller connectors. We then performed ultrasonic welding on all wire splices and covered all called-out wire with fabric tape.
Finally, the assembled part was placed on a custom harness board where the various breakouts were made. We additionally installed a loom, as well as all add-on parts.
In order to ensure the finished cable harness met precise client specifications, we compared the harness assembly against a harness board to confirm that our product possessed all proper lengths and connector orientations. We also performed a series of in-process and final visual inspections, as well as an electrical test. In addition, we spliced the jumpers to all drain wires, and then tested the unit’s performance.
Once assured that the cable harness fulfilled our customer’s unique product requirements, we delivered the completed unit to our client’s facility in Huntsville, Alabama. The finished harness met IPC-WHMA-A-620 standards for superior workmanship.