Cable & Wiring Harnesses

pump-manufacturing-portfolioConsolidated Electronic Wire & Cable (ConWire) is proud to offer a wide selection of robust, top-quality cable and wiring harnesses. Designed to organize and streamline multi-wire systems in aerospace, automotive, medicine, telecommunications, commercial buildings, and even home electronic applications, cable and wiring harnesses can be customized to meet almost any specification.


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Understanding Wire Harnesses

cable-assemblyWhile many professionals refer to cable assemblies and wire harnesses interchangeably, these multi-wire (or multi-cable) arrangements can be crafted differently to serve different purposes for unique environments and applications.

Simply put, a wire harness is the exterior covering, or sheath, that protects an inner conductor or bundle of conductors. These inner components may already have sheaths for insulation and protection, or they may rely on the wire harness to create an ideal operational environment. Either way, the wire harness provides critical organization at the heart of a system, and does so with a simple, straightforward, low-cost design.


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Custom Wire Harnesses

Wires and cables are indispensable tools for a wide range of today’s home and industrial systems, and harnesses allow technicians to create orderly, carefully fitted wiring solutions for any type of environment. Depending on the specific needs of an application, these harnesses can be built to accommodate systems up to 600 volts (UL) or 3000 volts (military), with high performance at temperatures ranging from -65 °C (-85 °F) to 250 °C (482 °F).

When evaluating a new cable or wire harness solution, remember to carefully consider the specific environment it will be used in and the temperature and conditions it will be exposed to. Evaluate all of the different cable types you may be able to use; custom wire and cable harnesses can be crafted with nearly limitless style and material options, including:

  • Wire ties
  • Lacing
  • Insulation materials of all kinds
  • Custom colors
  • Heat-shrink coatings
  • Custom labeling or barcoding
  • Four-color ink stamping
  • Individual tagging
  • Independent circuit IDs
  • Polypropylene, nylon, and paper fillers
  • Custom shielding

High-Performance Materials

In addition to ensuring optimal organization, a high-quality wire and cable harness will provide reliable insulation and protection for the conductors within. Harness materials should offer just the right fit for an application’s specific needs.

Some of the most common insulator materials include:

  • PVC, or polyvinyl chloride
  • SR-PVC, or semi-rigid polyvinyl chloride
  • Cellular polyethylene
  • EPDM, or ethylene propylene diene monomer
  • TPE/TPR, thermoplastic elastomers
  • PE, or polyethylene
  • Both low- and high-density polyethylene (LPDE and HDPE)
  • Cellular, or foam, polyethylene
  • PU, or polyurethane, as well as polyurethane and nylon blends
  • Low-smoke plenum copolymers
  • Polypropylene (PP) and cellular (foam) polypropylene
  • FEP, or fluorinated ethylene propylene
  • TFE, or tetrafluoroethylene
  • PTFE, or polytetrafluoroethylene
  • ETFE Tefzel
  • PVDF Kynar
  • ECTFE Halar
  • IRR/PVC, or irradiated polyvinyl chloride
  • XLPE, or cross-linked polyethylene
  • Vinyl

Harness Solutions

Bearing in mind relevant industry standards and specifications such as IPC/WHMA-A-620, there are countless ways to develop a harness or assembly to meet the needs of a particular project. And with various options available for shielding, fillers, materials, identification, and style, the most efficient organizational solution for your project is simply a matter of strategic engineering.

At ConWire, we’ve been helping clients develop these solutions for nearly 100 years. Our custom harnesses and assemblies can be found in a wide range of applications, including appliances, audio/video, aerospace, automotive applications, and medicine. All projects are supported by our state-of-the-art production facilities.

In addition to top-quality harnesses, we also offer braiding, wire crimping and terminations, custom-cut and shrink tubing, electronic wire and cable, power cords, and so much more. To learn more about our custom wire and cable harness solutions and discuss how we can help with your next project, check out our comprehensive eBook, “Creating a Custom Cable.”

Cable & Wiring Harness Capabilities

Wire End Configurations

Molex Terminations
Amphenol Terminations
AMP Terminations
Circuit Board Ready
Spade Terminals
Fork Terminals
Ring Terminals
Hard Wired
LED
Light Sockets
Molded
Overmolded
Metal Formed
Plastic Injection Molding
Tinned
Soldered
Switches
Stripped and Tinned
Ultra Sonic Welding
Crimped Ends
Heat Shrink Tubing

Insulation Materials

PVC - Polyvinyl Chloride
SR-PVC - Semi Rigid Polyvinyl Chloride
Cellular Polyethylene
EPDM - Ethylene Propylene Diene Monomer
TPE/TPR - Thermoplastic Elastomers
PE - Polyethylene
LDPE - Low Density Polyethylene
HDPE - High Density Polyethylene
Cellular (Foam) Polyethylene
PU - Polyurethane
Polyurethane / Nylon
Low Smoke Plenum Co-Polymers / PVC
PP - Polypropylene
Cellular (Foam) Polypropylene
FEP - Fluorinated Ethylene Propylene
TFE - Tetrafluoroethylene
PTFE - Polytetrafluoroethylene
ETFE Tefzel
PVDF Kynar
ECTFE Halar
IRR/PVC - Irradiated Polyvinyl Chloride
XLPE - Cross-Linked Polyethylene
Vinyl (PVC)
And many others

Conductor Materials

Bare Copper Wire
Tinned Copper Wire
Silver Plated Copper Wire
Nickel Plated Copper Wire
Copperweld/Copper Covered Steel

Voltage

Up to 600 V (UL)
3000 V (Military)

Temperature Range

-65ºC to 250ºC

Conductor Gauge

4 to 40 AWG

Conductor Cabling

1 Conductor to 60 pairs

Stranding Constructions

Solid
Bunched
True Concentric
Rope Lay

Conductor Coatings

Tinned Copper
Heavy Tinned Copper
Prefused Copper
Overcoat Copper
Top Coated Copper
Silver Plated Copper
Nickel Plated Copper

Shielding

Braided Wire
EMI/RFI Shielding
Mylar/Aluminum Foil
Mylar/Aluminum Foil & Braid
Spiral Serve Wire

Cable Filler

Polypropylene
Nylon
Paper

Wrapping

Tie
Heat Shrink
Lacing
Tape
Tube

Markers

Labels
Tags

Labeling

Bar Code
Four Color Ink Stamping
Circuit Identification

Quality Assurance

Consolidated Total Quality Management

Quality Control

Single Point Accountability

Testing

Standard UL, CSA & Industry Testing Procedures
Custom Testing Parameters Available Upon Request

Production Volume

100 Units to OEM Volumes

Typical Lead Time

3 Weeks to 10 Weeks

Additional Information

Industry Focus

Aerospace
Agriculture
Amusement
Appliances
Automotive
Broadcast
Commercial
Communications
Computer
Factory Automation
Gaming
Home Entertainment
Local Utilities
Marine
Medical
Military
Power Supply
Public Safety & Transportation
Renewable Energy
Robotics
Security
Solar Power Energy
Telecommunications
Wind Power Energy
Wireless
Industrial Machinery

Industry Standards & Approvals

ISO 9001
QS 9000
RoHS Compliant
CE
CSA
C-UL
HAR
Automotive J-1128
UL
NEC
VDE
OSHA
Category 5/6/7
Lead Free

File Formats

CAD Capabilities
DWG
PDF
.PPT
.XLS /.XLSX
.DOC /.DOCX