Competent Chinese Company Knowledgeable with Harness Assembly
Do you require Harness Assembly? Then you’ve arrived to the right spot. PCBMay can provide PCB Harness Assembly service as well as PCBs. We ensuring that you never have to worry about full system integration. Your interconnects are safe with us.
- Customers all throughout the world have endorsed us (US, Canada Europe)
- We are one of China’s PCB manufacturing leaders
- For your first major order, we’ll give you a free sample.
- Delivers on time, every time.
- If you require a third-party audit, we are willing to provide it.
Helpful Harness Assembly Services by PCBMAY
Harness Assembly of PCBs and other wires are required in certain situations, particular to your company. Your PCB assembly is in excellent hands with our professional crew.
We are a PCB manufacturing company with extensive experience. We’ve developed multilayer PCB manufacturing over the last 12 years. Harness Assembly is a service needed to connect Multilayer, Flex and Rigid-Flex PCBs.
Join the ranks of our satisfied clients. Purchase today!
Types of Harness AssemblyServices We Give You
Your Cooperative Harness Assembly Provider
PCBMay is a one-stop shop for all of your Harness Assembly and PCB needs. In this case, which we can the extra service for wiring to your PCB order.
Turn-key PCB services are something we excel at. In other words, we can design, construct, and ship your PCB order. You can specify the Harness Assembly required with the PCB products received from us.
For your PCBs and Harness Assembly inquiries, contact PCBMay right away! We can assist you.
Related to Harness Assembly
Harness Assembly Production Details As Following Up
|Base Material||KB、Shengyi、ShengyiSF305、FR408、FR408HR、IS410、FR406、GETEK、370HR、IT180A、Rogers4350B、Rogers4000、PTFE Laminates(Rogers series、Taconic series、Arlon series、Nelco series)、Rogers/Taconic/Arlon/Nelco laminate with FR-4 material(including partial Ro4350B hybrid laminating with FR-4)|
|Board Type||Backplane、HDI、High multi-layer 、blind&buried PCB、Embedded Capacitance、Embedded resistance board 、Heavy copper power PCB、Backdrill.|
|Copper Thickness||Min. 1/2 OZ, Max. 10 OZ|
|Maximum Board Size||1100*500mm(43”*19”)|
|Min laser drilling size||4mil|
|Solder Mask||Green, Black, Blue, Red, White, Yellow,Purple matte/glossy|
|Surface Treatment||Flash gold(electroplated gold)、ENIG、Hard gold、Flash gold、HASL Lead free、OSP、ENEPIG、Soft gold、Immersion silver、Immersion Tin、ENIG+OSP,ENIG+Gold finger,Flash gold(electroplated gold)+Gold finger,Immersion silver+Gold finger,Immersion Tin+Gold finger.|
|Min. Annular Ring||3mil|
|Aspect ratio||10:1(HASL Lead free、HASL Lead、ENIG、Immersion Tin、Immersion silver、ENEPIG);8:1(OSP)|
|Impedance control||±5ohm(＜50ohm), ±10%(≥50ohm)|
|Other Techniques||Blind/Buried Via|
|Via in Pad|
Here there’re many laminate material datasheets, they’re useful and helpful for you, please see them:
|SUPPLIER||PCB LAMINATE||TYPE||MATERIAL DATASHEET||TG||TD||DK(1MHZ)||DK(1GHZ)||DK(10GHZ)|
|Hitachi||MCL-BE- 67G||Modified Epoxy||DOWNLOAD||140||340||4.9||4.4||–|
|N4000-13EP SI||Modified Epoxy||DOWNLOAD||210-240||350||–||3.4||3.2|
|Stablcor||ST325||–||DOWNLOAD||Thermal conductivity:75w/m.k(with 1oz copper)|
|ST10||–||DOWNLOAD||Thermal conductivity:325w/m.k(with 1oz copper)|
|Bergquist||ht-04503||–||DOWNLOAD||Thermal conductivity:2.2w/m.k(with 1oz copper)|
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Your Professional Harness Assembly Provider—PCBMay
PCBMay makes your electronic connection arrangements simple. After you’ve finished determining your overall design, you’ll want to make sure it’s put together correctly. You want everything to be safe throughout this step. That is why you need our fantastic Harness Assembly service.
- All our services are done by PCB professionals
- We make use of upgraded tools, e.g. connectors, crimps, insulation material, lanyards, etc.
- Our installation effectively guards against magnetic faults (short-circuiting)
- We protect your components from overheating
PCBMay is a reputable PCB manufacturer in China. We promise to go to considerable efforts to ensure that you receive high-quality Harness Assembly service and PCBs.
Our devoted and well-trained workforce of more than 500 people sincerely cares about your satisfaction with our products and services. For any Harness Assembly inquiries, PCB assembly, or PCB design needs, you can contact us 24 hours a day, 7 days a week. Our Harness Assembly will undoubtedly meet your objectives.
We participate in trade exhibitions such as Electronica Munich and PCBWest to keep our industry knowledge up to date. We also do our own frequent training to ensure that our personnel is competent. When it comes to your Harness Assembly questions, we are confident that we can provide you with the appropriate response.
In addition, we have enough raw materials at our plant to satisfy PCB bulk orders. Prototyping PCBs is likewise, another area in which we excel. When we finish a Harness Assembly service, it adheres with the REACH and RoHS guidelines.
So don’t put it off any longer! Please contact us right away if you have any questions.
Harness Assembly: The Ultimate FAQ Guide
Are you worried about arranging electronic connections in your projects?
Harness assembly is a reliable process to connect all components safely. Its features ensure you put everything together properly.
PCBMay is a reputable harness assembly service provider in China. We assure you of a proper wire connection that protects the devices from overheating and short circuits.
This FAQ guide will help you understand this assembly service. Let’s dig it deeper.
What Is PCB Harness Assembly?
PCB harness assembly refers to the combination of different wires and cables for signal transmission in the PCB. This process effectively connects PCB components to transfer power or electric signals to them.
Harness cable assembly is compatible with both active and passive components used in high-volume PCBs. A regular wire harness assembly process deals with dozens of electric wires that join around hundreds of PCB materials.
Its cost-effective features and digital connection facility make it reliable to the PCB manufacturers. Besides, a harness assembly board goes through multiple tests. So, there is no doubt about the reliability and functionality of this PCB assembly service while making a PCB.
Moreover, this assembly provides excellent support to the group of wires and cables. That’s why these wires remain functional under extreme mechanical pressures. In a nutshell, the harness cable assembly is an outstanding solution to solve dimensional and electrical problems related to wiring.
Watch this video to get a visual concept on wire harness assembly:
What Are The Main Parts Of PCB Harness Assembly?
The principle parts of PCB harness assembly include-
Harness Assembly Features In PCB Manufacturing
What Applications Are For Wire Harness Assemblies?
Wire harness assemblies have numerous applications in the electronic world. Their premium-quality service makes the wire harness very popular in different industries. The most notable applications of this PCB assembly service include-
The aerospace industry gets benefits from wire harness technology. Usually, aerospace equipment requires high robustness and excellent durability. The wire harness is reputable for providing these features to the electronic materials used in this sector.
The base element of an aerospace PCB is Rogers material. This PCB material is supportive of wire harness technology to a large extent.
Automotive printed circuit boards consist of this PCB assembly. Here, the manufacturers incorporate different high-quality PCB mechanisms like press-fit, blind vias, etc, while connecting the PCB components.
Usually, the wire harness effectively manufactures automotive cars, robotics equipment, etc.
Harness PCB assembly service improves the functional properties of versatile consumer electronic products. Such as
- Washing machine
- Microwave oven
- Air cooler
This assembly offers service for both prototype PCB and multilayer designs. That’s why manufacturers prefer the wire harness technology for consumer electronics.
Industrial products like the motor driver, converter, transformer, controller, etc are compatible with harness assembly boards. This PCB assembly reduces the production time of industrial PCBs to a certain extent.
Medical instruments require high thermal conduction and tolerance power. Harness assembling incorporates high TG materials to connect the wires. That’s why you can use this assembly in manufacturing numerous medical instruments like scanners, ECG machines, testing equipment, etc.
Like Aerospace circuit boards, you have to ensure reliability in signal transmission in military instruments. These components also require high rigidity. The military harness assembly process ensures reliability during data propagation.
It also provides dimensional stability in military equipment used in communication, such as radar navigators, wireless networking systems, etc.
Aerospace Harness Assembly
What Are The Processes Of PCB Wire Harness Assembly?
PCB wire harness assembly process is a combination of interlinked tasks. You need to ensure excellent performance in each segment due to its interconnection. Here, are the basic steps for PCB assembling the wire harness for you.
The pre-assembly segment is crucial to optimize this assembly. During this part, you have to cut, strip, and identify the circuit board wires first. You can use a crimp center to cut the cables according to the required length and metal terminals.
Besides, you can insert the wires into a conductor housing. It allows the mixing of male and female groups of bundles.
The entire process can be classified into several steps. Such as
The first step is installing the PCB wires. Then, you need to do sub-assembling in the wire harness assembly board.
The next step is PCB routing for wire connections. You should route the wires and sub-assemblies by using sleeves.
Then, apply wraps or taps to any kind of brunch-outs. The rest is using crimping terminals to wires and cables.
In the end, wires get bound with an external PCB covering. Automated processes for these PCB assemblies are not very convenient to the manufacturers. That’s why manual assembly is common for different applications.
Harness Assembly Process
What Are The Benefits Of PCB Harness Assembly?
Harness assembly improves the quality of printed circuit boards to a great extent. It includes multiple positive features to basic and advanced level high-density PCBs. Its most noteworthy benefits are-
Harness cable assembly takes care of the electronic connection between PCB components. This assembly service is reliable for sensitive signal transmission systems. There is almost no chance of losing data during propagation. That’s why it has excellent applications in communications.
The wire harnesses optimize the space in PCB manufacturing by making groups of wires. It allows the circuit board designer to design the component placement more efficiently.
It supports custom solutions for specific applications. Its design and processes are highly flexible. So, you can upgrade the circuit board design and wiring through proper customization.
Long Service Life
This PCB assembly service ensures a long shelf life for the wires and cables used in PCB productions. It offers excellent safety to both cables and equipment.
You can find wire harnesses in a wide scale of length and sizes. Its availability promotes the features properly. This property makes the task of PCB manufacturers easy.
Wiring in electronic appliances often suffers from low durability. But printed circuit board wirings consisting of wire harness assembly process offer high-class thermal and mechanical resistance.
Besides, this PCB assembly handles high current loads with great reliability. That means a well-designed wire harness is free from the complications due to overheating and overloads. Its moisture resistance is impressive enough to utilize it in highly humid conditions.
This PCB assembly is distinctly durable. That’s why it remains functional in different environments. The impressive functionality of the wire harness technology keeps it always one step ahead.
Wide Range Of Temperatures
Wire harness PCB assembly provides compatibility with a wide range of temperatures. Its thermal management is commendable. SoIts construction materials are also thermal resistive. , it can handle thermal forces effectively.
That indicates its superb thermal efficiency without compromising the performance in electronic applications.
The wire harness assembly design is stable to a large extent. You can incorporate this assembly in a multilayer stackup of printed circuit boards. Again, it is supportive of surface mount technology. That means you can apply it in high-density and high-frequency data transmission due to its reliable designs.
PCB harness cable assembly supports lead-free soldering to a certain extent. That means it is an eco-friendly circuit board assembly service. If you are a flag-bearer of green electronics, you should rely on wire harness assembling for PCB.
The cost-effective specifications allow you to apply the wire harness cable assembly at affordable costs. You can easily manage the entire wire connection. Besides, this assembly is compatible with high and low-volume PCB manufacturing.
So, you can optimize the cost-performance of the circuit board wiring.
Advantages Of Harness Assembly
Can You Replace The Wiring Harness In Automotive PCBs?
Yes. The wiring harness of the automotive PCBs is replaceable and repairable. The reasons are-
- Wire harness assembly provides a manual that contains all conventions for color-coding. So, a skilled technician can easily replace the wire harness.
- Harness cable assembly groups the PCB wires and cables. That’s why you can replace the wire connections of a specific part of automotive PCBs.
- Its design is very stable. It also allows customization in wirings.
Harness Assembly In Automotive Circuit Board
What Types Of Wire Terminals Are Used In Harness Assembly?
The wire terminals usually terminate the conductor to a fixed position and ensure a reliable electrical connection. They have multiple types concerning screw and wire sizes. Such as
- Ring Terminals
- Ferrule Terminals
- Hook Terminals
- Spade Terminals
- Bullet Terminals
- But Terminals
- Quick-disconnect Terminals
- Flagged Terminals
Besides, you can classify the wire terminals based on their insulation properties. Such as
- Partially Insulated
- Fully Insulated
Wire Terminals In Harness Assembly
Why The Wire Harness Assembly Is Effective For Heat Dissipation?
The wire harness assembly process is effective for heat dissipation because-
- Wire harness assembly handles electrical shock and static discharge efficiently.
- It supports the placement of thermal vias and PCB copper coins.
- It maintains a constant airflow in the wire connections.
- This assembly prevents dust contamination.
Custom Design For Wire Harness Assembly
Why Complex PCB Wiring Harness Can Not Be Fully Automated?
It is a common concept that an automated wire harness for complex PCB designs takes less time and is more efficient. But this conception is not applicable in all cases. An automated wire harness assembly harness requires high-level precision and machinery knowledge.
PCB Wire Harness Assembly
Due to a lack of this expertise, the manual wire harness is getting popular day by day. It is more economical than automated wire harnesses. But the manual process takes huge time compared to other cable assembly types.
That’s why manufacturers usually apply both processes concerning the assembly pattern. You can depend on the manual wire harness for the following-
- To bind the PCB components by using tapes.
- To Install wires of various sizes and lengths.
- To use crimp-on some wires.
Though automated harness is complex, it improves the quality of the following task-
- To solder the terminal points of the wire.
- To crimp both sides of wires.
- To cut and strip through automated machines.
Which Component Mounting Process is the best In Harness Assembly?
SMT (Surface Mount Technology) and THT(Through-hole Technology) are two effective component mounting processes for harness assembly boards. Both of these processes provide useful positive features in wire connections. But there are some technical differences between them. Such as
The rate of connecting SMT components is around a thousand times lesser than the component wiring used for THT PCB assembly. So, SMT is a highly time-effective component mounting technique.
Surface mount technology offers outstanding functionality in high-density PCB. Here, the formation of the wire connections has high reliability.
In contrast, through-hole technology can’t deliver reliable wirings during PCB assembly.
Amidst the high vibrating environment, the SMT harness renders excellent performance. But, THT is not as durable as SMT in oscillation conditions.
SMT harness cable assembly is economical. It requires fewer drilling holes compared to THT.
Surface mount devices provide impressive performance in managing thermal pressures. The wire harness assembly with SMDs supports the implementation of thermal vias for proper heat drain.
Surface Mount Technology Assembly For PCB Wire Harness
What Are The Differences Between Wire And Cable Harness Assembly?
There is a little bit of confusion between the wire harness and cable harness assembly. We are here with some differentiating features between these two assemblies. Let’s see.
Wire assembly usually covers single wires. You can easily pull out a wire from this assembly. But the cable assembly deals with many wires bundled through a single sleeve.
The wire harness assembly is more economical than the cable assembly.
The wire assembly has extensive use in aerospace, military, and medical industries. You can apply it in domestic and industrial zones.
Difference Between Cable Assembly And Wire Harness
On the contrary, the cable assembly is highly applicable in motor-based industrial equipment.
Check this video to get a better idea:
How Does Harness Assembly Protect The PCB Wires From Damage?
Harness assembly ensures safety for the circuit board wires through their great assembling. This assembly incorporates an effective covering to make the PCB wires and cables tolerant to various damage factors.
Here, a protective sheet made of thermoplastics or thermosetting materials provides sufficient protection to the wires. That’s why you can implement these cables and wires in electronic systems and equipment.
Durable Wire Harness Assembly
What Are The Main Challenges Of The Harness PCB Assembly?
The most noteworthy challenges of the harness assembly include-
- The geometrical challenge is to fit the wire harness or cable assembly in a specific space.
- The electrical challenge is to keep the group of wires protected from environmental, electrical, and mechanical pressures.
Harness PCB Assembly Challenges
How To Test Harness Assembly?
Testing is a vital part of the wire harness assembly process. You can check the functionality of this type of effective PCB assembly service manually and automatically. The most common and reliable tests for harness cable assembly are described here for your convenience.
Flying Probe Test
The flying probe test involves electrical probes to touch the circuit boards in different directions. When these probes touch the PCB surface, the inspector if this test generates a signal.
Then, you can see the values of different features like the voltage, current, power, etc. It takes a considerable time to test.
But the flying probe test is free from extra fixtures. So, its cost is within the range of low-budget manufacturers.
The AOI test depends on computer-based inspection. Here, the AOI machine compares images of wire harnesses with ideal wirings. This test effectively identifies the missing connections, loose points in circuit board designs, etc.
Since the entire process is automated, the AOI test is not economical. If you are dealing with large-scale PCB productions, you should rely on the AOI test.
Automated X-ray Inspection
The AXI (Automated X-ray Inspection) involves the penetrating power of the X-ray. It is worthwhile to detect faults in critical portions of the circuit board wiring.
Usually, it deals with dimensional defects of PCB box build assembly. This test is also expensive. So, if you have budget constraints, this test is not appropriate for you.
Solder Float Test
This test checks the thermal resistance of cables used in connecting the PCB components. Here, the inspector provides high thermal pressure and observes the behavior of PCB.
AOI Test For PCB Harness Assembly
How To Ensure High-Quality Harness Assembly?
You can ensure high-quality harness assembly if you consider the following factors.
- High-class materials
- Effective harness assembly tools
- Proper use of automation
- Quality inspection
- Temperature control
- Avoiding extreme humid situations
- Trustworthy assembly service provider
PCB Wire Harness Assembly Quality Control
What Are The Key Factors To Choose Reliable Harness Assembly Service Providers?
Choosing a reliable company that provides worthwhile harness assembly is a crucial thing. If you fail in this section, your whole project can be vain. That’s why you need to consider some vital factors while making your choice.
The following are the key factors for this purpose. Let’s have a look.
A competent assembly service provider should have upgraded tools for safe wire connections. You must consider this issue while looking for a trustworthy company for this assembly.
Again, this assembly includes PCB testing. You need to check the availability of equipment for automatic and manual tests. The AOI test, X-ray inspection test, etc involve high-quality equipment. So, a PCB maker must have such facilities with a well-structured factory.
PCB Assembly Experience
Harness technology involves the arrangement of electronic connections during circuit board manufacturing. That’s why it requires an experienced service to achieve the optimum output of this PCB assembly. You should focus on this issue while searching for a harness PCB assembly service provider in China.
Your harness PCB assembly service provider should have certification from reliable organizations, like RoHS. You must check that their products fulfill the requirements of IPC. Then, you can rely on its assembly service.
Knowledge About Modern Technology
The technicians must have up-to-date knowledge about this assembly. So, you must check whether the manufacturer has skilled professionals or not.
If they are not familiar with PCB harness cable assembly, they can’t provide custom solutions and modifications concerning the client’s demand. Besides, high-level expertise is essential to optimize automated harness assembly software-based designs.
Competitive Assembly Cost
You should look for a PCB assembly service provider for harness cable assembly that offers cost-effective services. As cost is an influential factor, you have to compare the assembly cost to its competitors and then decide.
A trustworthy manufacturer needs the capabilities of producing materials. Again, it should manage PCB materials from reliable sources.
You will get an idea about the customer service of harness assemblers from customer reviews. Besides, it needs to deliver 24/7 sales and technical support through skilled engineers.
We have been providing dependable assembly service for more than 15 years. Our PCB professionals are highly experienced in using wire harness assembly tools. You can rely on us to handle your electronic projects.
The harness assembly process is reliable for ensuring perfection in printed circuit board designs. The way it functions and handles component damage is excellent. That’s why this assembly has become popular in versatile electronic applications.
If you are looking for an expert harness or cable assembly service provider, PCBMay will be the best choice. We have a reputation for delivering high-quality circuit board assembly service.
Contact us to get more information about the PCB assembly service. We tried to keep this FAQ guide informative and straightforward. We hope it will benefit you in meeting your objectives.