In the field of electronics, the terms wiring harness, wiring loom, and cable assembly are often used interchangeably. This might be correct from the general outlook of wiring harnesses, but when you get into the specifics, the terms are quite different. All three refer to wires or a combination of wires that transmit electrical power, data, or signals from one point to another, with the last two either being via current or light (optical fiber). But that’s where the similarities end. Here are the differences between these three terms.
What Is a Wiring Harness?
Wiring harnesses provide the most basic wire setups of the three. The term harness on its own refers to a safety device used for control or fall protection. In electronics, a harness is basically a method used to safeguard wires and keep them tidy when arranged to follow a pre-defined layout. These wiring harnesses usually have multiple wires cut to the required length that are tied together using tape, heat-shrink tubing, or cable ties to keep them tidy, save space, and prevent physical damage from abrasion or friction.
The individual wires in the harness can be terminated using one or more connectors, but some can be left open for permanent joining, such as by soldering or crimping. In complex configurations, the wiring harness can have different wires branching out at multiple points.
One of the benefits of having such simple protective mechanisms in wiring harnesses is it eases troubleshooting if there are faults, such as short or open circuits. Producing them is also cheaper and quicker. However, these wires aren’t protected from harsh external conditions, such as moisture, and can unravel due to excessive vibrations, heat, or cuts that damage the tape, tubing, or cable ties.
From the origins standpoint, wiring harnesses were the first to be introduced in the market out of necessity in the car manufacturing industry. Automotive manufacturers had to overcome the challenge of individual car wires becoming loose or damaged due to excessive vibrations in the vehicle. So they popularized the use of wiring harnesses in the 1920s and 1930s, which were cheap to mass produce at the time because cars had similar wiring setups, at least for each car brand.
What Is a Cable Assembly?
Cable assemblies are similar to wiring harnesses in the aspect of having wires arranged to follow a predefined layout. But cable assemblies feature a distinct protective outer sheath made of rubber, plastic, polyurethane, or vinyl that protects the wires inside from harsh environmental conditions, such as moisture, fire, extreme temperatures, oil, chemicals, or physical damage.
A cable assembly with an IEC 60320 C13 connector on one end and NEMA 5-15 plug on the other
Some can even have overmolded connectors and socket plugs, such as most TV or desktop computer power connectors. Cable assemblies can also have a combination of individual wires and multi-core cables internally, all of which are protected from the elements by the outer sheath.
But while this structure increases the build quality of the cable, it also increases its costs and can make it difficult to spot electrical faults for repairs.
What Is a Wiring Loom?
Also known as cable looms, wiring looms are more complex versions of wiring harnesses. They contain multiple and different types of cables and wires, each with its terminations and components. The idea behind developing wiring looms is to create space-saving wiring designs that reduce the wiring footprint in the final product.
Think of the electrical wiring in modern cars or planes for parts like engines. These looms are incredibly complex because they have multiple wires and connectors, all wrapped up into a space-saving wiring design. White goods like washing machines also feature wiring looms.
Besides space saving, the other benefit of using wiring looms is the ease of installation, which also reduces the overall installation time.
Each part of these looms has the specific sheaths and insulations that safeguard the wires from harsh external conditions, such as extreme engine heat.
Wrapping Up
Each of these types of wires has its own applications and making them in-house can be costly and challenging. The best way to keep costs manageable is by outsourcing wiring harness, wiring loom, and cable assembly production to specialist manufacturers, who incorporate internal quality assurance and industry standard procedures to make high-quality wiring products with long service lives. This is especially true for special-purpose cables, such as RF or marine cables, which have to be designed and manufactured to meet certain performance and durability standards. Companies like Cloom Tech and Wiringo provide custom wiring harness manufacturing for such specialty-purpose cables, as well as the general type, and they have the experience and expertise to make high-quality wiring products to meet your needs. Reach out to them for more information.