Wire Harness Components 295
This class provides an overview of the components that make up a wire harness. A wire harness is a pre-assembled collection of electrical wires that are organized according to function. Wire harnesses include many different wires and cables that are covered with insulation and connected via devices such as terminals and connectors. Binding devices like cable ties, cable clamps, and sleeves are used to organize wires.
After taking this class, users will be able to identify the components of a wire harness and describe their functions. Wire harnesses are used in many devices and machines in manufacturing, both in the products that are produced and in the equipment used to produce them.
Number of Lessons 11
- Wire Harnesses
- Twisted Pair Cable
- Shielded and Unshielded Twisted Pair Cable
- Coaxial Cable
- Wire and Cable Review
- Temporary Insulation
- Terminals and Connectors
- Binding Devices
- Final Review
- Describe wire harnesses.
- Describe the wires used in wire harnesses.
- Describe twisted pair cable.
- Describe unshielded and shielded twisted pair cable.
- Describe coaxial cable.
- Describe wire insulation.
- Describe temporary insulation used in wire harnesses.
- Describe terminals and connectors used in wire harnesses.
- Describe binding devices used in wire harnesses.
AC. A current formed when electrons flow in a one direction and then the opposite direction. Alternating current usually reverses direction 60 times per second.
AC. Electricity that reverses direction at regularly recurring intervals of time. Alternating current switches direction 60 times per second, or 60 hertz.
The strength of an electrical current. Amperage is measured in amperes (A), or amps.
A continuously variable electrical signal. Analog signals differ from digital signals in that small fluctuations in an analog signal are meaningful, whereas digital signals tend to only detect changes over a certain threshold.
A measurement of the amount of information or data that can be sent over a network in a period of time. The higher a network's bandwidth, the more information it can carry.
A wire connector that consists of a pin terminal and a mating cylindrical receptacle. Barrel connectors may use groove terminals that lock into threads or teeth in the receptacle.
A single large conductor or bundle of smaller wires insulated in a jacket. Cables allow electricity to travel from its source to its destination.
A strong nylon or steel device used to bind wires together. Cable clamps can be removed without being destroyed and are used for long, heavy wires.
A strip of notched nylon used to bind wires together. Cable ties must be destroyed to be removed.
A type of cable that consists of a central metal conductor surrounded by an insulating layer, a braided metal shield, and a protective jacket. Coax, also known as coaxial cable, can transmit electrical signals and radio frequency signals.
A type of cable that consists of a central metal conductor surrounded by an insulating layer, a braided metal shield, and a protective jacket. Coaxial cable, also known as coax, can transmit electrical signals and radio frequency signals.
A material that allows free movement of electrons and therefore enables the easy flow of electricity. Conductors are typically metals.
A two-part device that attaches to the end of a wire to create an electrical connection. Connectors consists of mating conductive parts that complete a circuit when attached to one another.
A metal that is ductile, conductive, and corrosion resistant. Copper is one of the most commonly used conductive metals in the electrical field.
The central wire in a coaxial cable. The core is the part of the coaxial cable that transmits electrical and radio frequency signals.
The flow of electricity through a circuit. Current is measured in amperes (A), or amps.
The amount of voltage a material can withstand before beginning to break down. Materials with high dielectric strength make good insulators.
The process by which information is divided into a positive and negative signal that, when recombined, recreate the information. Differential signaling reduces noise from other EMI sources because stray signals are negated by the recombining of the positive and negative signals.
The amount of electricity that can safely flow through an electrical device or circuit without it overheating. Electrical capacity is an extremely important electrical quantity.
Unwanted changes in the voltage of the current traveling on a wire, caused by another electrical source. Electrical noise is reduced by twisted pair cables and shielding.
Voltage, current, or frequency that communicates information between two devices. Electrical signals are either analog or digital.
A stretchy plastic tape that acts as an electrical insulator. Electrical tape can be used to temporarily repair damaged wire insulation, but it is not recommended.
EMI. Disruption of the transmission or reception of a signal caused by a magnetic field. Electromagnetic interference can be prevented by using certain types of cables and wire configurations.
Electromagnetic interference. Disruption of the transmission or reception of a signal caused by a magnetic field. EMI can be prevented by using certain types of cables and wire configurations.
A system for connecting a number of computer systems to form a local area network. Ethernet cables transmit electrical signals.
An extremely thin strand of metal. Filaments can be combined to make a stranded wire.
An adhesive strip of metal foil used to shield wires. Foil tape is used as shielding in shielded twisted pair wires.
A sheet of metal foil used to shield wires. Foil wrap is used as shielding in shielded twisted pair cables.
The diameter of a wire. Higher gages indicate smaller diameters.
A wire that provides a low-resistance path to ground for fault currents. Grounding conductors help prevent stray currents from causing electric shock or damaging equipment.
heat shrink tubing
A sheath of insulating material that decreases in size when heat is applied to it. Heat shrink tubing can be used to temporarily repair wire and cable insulation, but it is not recommended.
A wire connector surrounded by an air- and water-tight material. Hermetically sealed connectors are used in electrical devices at risk of getting wet or being exposed to corrosive gases.
A coil of conducting wire that creates a magnetic field when current passes through it. Inductors are used to energize devices.
A material that does not conduct electricity. Insulation is applied to conductors like wires to prevent the unintentional flow of electricity.
A protective outer layer of insulation on a cable. The jacket protects the wires inside the cable from damage and prevents signal interference.
The area in and around an energized conductor in which a magnetic force exists. Magnetic fields exhibit the powers of attraction and repulsion.
A machine that converts one form of energy, such as electricity, into mechanical energy or motion. Electric motors operate on the principle of magnetic induction.
A group of hardware devices connected through by cables or by wireless methods. A network allows multiple devices to communicate and share information.
A synthetic plastic that is flexible and durable. Nylon is a good insulator and is used in cable binding devices.
Occupational Safety and Health Administration
OSHA. A government agency under the U.S. Department of Labor that sets the standards for safe working conditions in the United States. The Occupational Safety and Health Administration ensures that employees work in safe and healthy environments.
A measurement of the number of voltages in one alternating current (AC) cycle. Alternating current is either single-phase or three-phase.
Having a positive or negative charge. Polarity determines the direction in which current tends to flow.
A common synthetic thermoplastic that is highly resistant to electricity and heat. Polyethylene is often used as insulation on conductors.
A lightweight material that generally has high corrosion resistance, a high strength-to-weight ratio, and a low melting point. Polymers are more commonly referred to as plastics.
PVC. A thermoplastic that can be either rigid or flexible. Polyvinyl chloride is often used as insulation on wires.
programmable logic controller
PLC. A processor-driven device that uses logic-based software to provide electrical control to machines. Programmable logic controllers are used in factory automation.
A type of electromagnetic signal capable of transmitting audio, video, and other types of data. Radio frequency signals can be transmitted through coaxial cables.
A device that restricts the flow of electric current. Resistors limit current flow and produce work such as heat or light.
An elastic polymer made from natural or artificial latex. Some rubbers can be used as insulating materials.
shielded twisted pair
STP. A type of twisted pair cable that includes a layer of metal shielding between the intertwined wires and the protective outer jacket. Shielded twisted pair cable is used for network communications.
A protective layer in an electrical cable that protects the wires within from electromagnetic interference. Shielding can be made from foil tape, foil wrap, or other metal materials.
A tubular plastic device used to bind and protect cables. Sleeves cover the length of bundled of cables and protect them from damage.
A wire connector that consists of a spade terminal and a mating receptacle. Snap-on connectors can be quickly connected and disconnected.
An output device that uses a conductive coil to convert electrical energy into linear mechanical motion. Solenoids are often used to control valves in fluid power systems.
A conductor made from a single wire. Solid wires are often used in homes and offices.
A type of terminal that has a flat, spade-like shape. Spade terminals can be part of a snap-on connector or be snapped onto a bolt to form an electrical connection.
A segment of the OSHA standard for the construction industry that states that electrical equipment must be approved. Standard 1926.403(a) has been interpreted to mean that only equipment that has been tested and approved by a Nationally Recognized Testing Laboratory should be used.
A strong metal consisting of iron and carbon, usually with small amounts of other elements. Steel is used to make cable clamps.
Shielded twisted pair. A type of twisted pair cable that includes a layer of metal shielding between the intertwined wires and the protective outer jacket. STP cable is used for network communications.
A conductor made up of two or more wire filaments. Stranded wire is more flexible than solid wire.
A fastener that connects some cables in electrical systems. Studs can be used to connect to fork terminals and ring terminals.
A type of submerged pump that pulls water from a type of well, called a sump. Sump pumps have hermetically sealed electrical connections.
A proprietary polymer. Teflon is used as insulation because of its dielectric properties and its resistance to environmental damage.
A conductive device installed at the end of a wire to connect it to another wire or electrical device. Terminals come in many shapes and sizes and are often part of two-piece connector.
twisted pair cables
A type of cable that consists of pairs of insulated wires that are intertwined around each other and covered with a protective outer jacket. Twisted pair cables use a positively charged wire and a negatively charged wire, as well as differential signaling, to prevent electromagnetic interference and reduce noise.
A wire connector that consists of a notched terminal and a mating receptacle. Twist-lock connectors lock into place when twisted.
unshielded twisted pair
UTP. A type of twisted pair cable that does not include shielding between the intertwined copper wires and the protective outer jacket. Unshielded twisted pair cable is used in most homes and offices.
A collection of wires organized and bundled according to function. A wire harness, also known as a wire harness assembly, facilitates easy installation and saves space.
wire harness assembly
A collection of wires organized and bundled according to function. A wire harness assembly, also known as a wire harness, facilitates easy installation and saves space.
A slender rope of drawn metal used to transmit electrical current or signals. Wires usually consist of the metal conductor itself and a covering of insulation.