Cable Assemblies Versus Wire Harnesses

One person’s cable assembly is another person’s wire harness.
By: Bud Kinzalow
 
May 5, 2011 - PRLog -- Cable assemblies and wire harnesses, the words are used all the time and often interchangeably.  One person’s cable assembly is another person’s wire harness.  Is there a difference, and if so does it really matter?  This article will show how to tell the difference, and give pros and cons for each.

Why would it matter what a bunch of wires is called?  Let’s use an example we can all relate to – food.  Most likely all of us have seen something on a menu at a restaurant and didn’t know what is was, and usually we ask someone at the table with us or the waiter.  But what if we didn’t and ordered noodles expecting pasta?  They look the same, but don’t really taste the same.  Or say we order tuna, expecting sushi, but we are served tuna salad instead.  Both are fish, but are decidedly different.  The same is true with cable assemblies and wire harnesses; while they both have wire they are decidedly different.

A cable, which is used to make a cable assembly, is a grouping of wires that are covered by an extruded sheathing.  Typical this sheathing is a thermoplastic such as polyvinylchloride, thermoplastic rubber or polyurethane.  In some special instances a thermoset material such as chlorinated polyethylene, chlorosulfonated polyethylene or EPDM hydrocarbon rubber.  Whether thermoplastic or thermoset material is used the key is the individual conductors are covered by a compound extruded around them.  This layer is in addition to the insulation on the individual wires providing additional protection from heat, moisture, abrasion, compression and other hazards the cable assembly might experience.

A wire, or conductor, which is used to make a wire harness, is an individual strand or group of strands covered by an extruded sheathing.  Again, this sheathing can be thermoplastic or thermoset, however in the case it is just a single layer.  When wire harnesses are made a group of individual wires are assembled together and typical “bound” in place with a mechanical device such as a cable tie, heat shrink, tubing or woven braiding.  Since the wires have only the one layer of sheathing the amount of protection from the environment is much less.

So what are the pros and cons of a cable assembly?  Some pros include, as mentioned above, increased protection from the environment due to the extra layer of plastic.  Also, having all the conductors in one bundle makes a neater and more convenient package which can be quite useful if the cable must be routed through or around equipment or components.  Having a cable also can allow the connectors on the end to be over molded, thus sealing the entire cable from the environment.  Two cons are an increase in size and weight, and typically the cost is higher due to the extra material and labor.

And the pros and cons of a wire harness?  These are usually the opposite of cable assemblies.  Pros include smaller size and weight, and lower cost since the extra material and labor is not used.  The cons are an increase in environmental vulnerability since the individual wires are exposed and the possibility of the wires “catching” on items during installation.

Since the differences are quite apparent what are some typical places each are used?  Cable assemblies are found in many exposed uses such as medical devices, industrial controls, military electronics and security products.  Wire harnesses are most often found inside products such as computers, vehicles, control cabinets and electronic assemblies.  So much like ordering food, when designing or buying a CABLE ASSEMBLY or WIRE HARNESS it is critical to know what you want.
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