The assembly of wiring harnesses arose from customer demand. An activity that fits perfectly with the complete construction of mechatronic devices. Meanwhile, we at BS&i Mechatronics have built up years of experience in assembling wire harnesses. This experience covers a wide range of applications and sectors with a wide variety of types of wire harnesses. The applications for the wire harnesses we build currently range from simple devices to complex machinery and medical equipment. Wire harness assembly takes place within the same organizational frameworks as device assembly. This combined with our craftsmanship built up over the years and our specific methods means that we deliver wiring harnesses that fully meet your requirements.
Type of wiring harnesses
Although we assemble completely according to our customers’ specifications, in basic any type of wiring harness can be built by us. The overview below gives an impression of this:
- Single wires: Single wires fitted with contacts and connectors. The thicknesses we currently handle range from:0.29 mm2 (AWG 26) to 50 mm2 (AWG 0/1).
- Multiple wires and cables: These are cords and cables with 2 or more conductors, possibly equipped with shielding and or protection.
- Variety of applications: This involves the use of an individual wire for a special application such as: power, data, sensors, high power, high voltage. The composition and materials of these wires differ according to the application.
- Different conditions: The wires come for a variety of conditions such as: high temperatures, waterproof and long lengths.
- Composite wiring harnesses: These are wiring harnesses constructed from individual wires, as described above. Currently, the number of wires that the wiring harness is composed of ranges from 2 to 350.
- Contacts: There is no limitation in this either. The number of types of contacts we currently process is legion from common types to the more exotic ones.
- Connector enclosures: These can be single enclosures or composite enclosures. Optionally provided with a shell.
- Splices: Connections and splices of wires with each other are performed with crimped splices. For high-vibration environments, splices are soldered.
- Added components: In a number of cases, a wire or wiring harness needs to be fitted with other components, such as resistors, sensors and switches. There is no limitation in this as well.
- Wrapping: In the end, the wiring harness can be clad in various ways such as shrink tubing, wrapping, split tubing and dense tubing.
Applications of our wiring harnesses
The wires and wiring harnesses assembled by us are used in a variety of industries and applications. To this we place no limitation. We currently assemble wire harnesses for the following markets:
- Medical: Patient-related equipment covered by the MDD (Medical Device Directive).
- Paramedsch: Equipmentused by and for persons and not covered by the MDD (Medical Device Directive).
- Food: Devices used in the hospitality industry intended for dispensing food-related products.
- Heavy Equipment: Vehicles such as excavators and rail applications.
Why choose BS&i Mechatronics?
Cable harnesses are a crucial part of modern electronic and mechatronic systems. They ensure that the various components of a device function correctly and work together. In addition, a properly manufactured wiring harness increases the efficiency, safety and reliability of your equipment. At BS&i Mechatronics, we understand better than anyone how important the function of a wiring harness is. Our knowledge and experience come from our background in equipment assembly. This allows us to perfectly apply our technical know-how and advanced processes when assembling high-quality wiring harnesses. We do this through the use of:
- Self-developed methods: These methods were developed to ensure maximum process control with minimum chance of error.
- Customization: The wiring harness is assembled and tested fully to specification. Methods and execution are fully tailored to your specifications, applications and requirements.
- Our organization: Wire harnesses are assembled a well established organization that meets ISO 9001 and ISO 13485 (for medical applications) standards.
- Flexible production: We adapt production to your needs such as single piece, prototype and medium series production.
Our process for wiring harness assembly
We use a structured approach focused on quality, reproducibility and efficiency. This process consists of four phases:
- Procurement and Preparation:
- Selection of components and materials through our extensive supplier network, fully tailored to customer specifications.
- Preparation of cables by cutting, stripping and marking.
- Shrinking contacts.
- Assembly:
- Laying wires and placing contacts in connectors….
- Application of splices, by crimping or soldering.
- Integrate special components such as resistors, sensors or switches.
- Application of shells and protection by tubing or wrapping.
- Number wires and connectors, if desired.
- Testing and quality control:
- Measurement of leads for optimal functionality.
- Visual inspection for a flawless finish.
- Inspection and testing as per our customer’s requirement.
- Packaging and Delivery:
- Package carefully to avoid damage during transport.
- Just-in-time delivery according to your logistical requirements.
Contact us for your wiring harness solutions
Do you have a specific need or challenge in the field of wire harnesses? Our team of specialists is ready to support you. Contact us today through Contact or call us at 0492 830126. Together, we will realize a solution that fits your project perfectly.
