How to Select Wire and Cable Harness Accessories

Cable Ties. Image Credit: All-Spec       Tube Clamp. Image Credit: Ark-Plas      Adhesive Mount Clip. Image Credit:Ark-plas

Wire and cable harness accessories are used to bundle, clip, clamp, label, guide, and protect wires and cables.

What are Wire and Cable Harnesses?

A wire harness is a string of cables and/or wires which transmit informational signals or operating currents. The number of cables included in the harness will depend on the intended purpose for the wiring and the amount of current or data that must be transmitted in order to complete the tasks. The size of the harness will depend on the number of cables included in the configuration, which is often determined by the amount of energy that must be conducted through the system. They are typically found in vehicle engines and industrial machinery. Wire harnesses must meet regulated safety standards and are routinely checked for signs or wear and tear.

Wire and cable harnesses are often customized with a variety of accessories to suit the specific needs of the user.

Selection Criteria

The GlobalSpec SpecSearch database allows industrial buyers to select wire and cable harnesses accessories by type of accessories, material, design specifications, and features.

Product Accessories

There are a variety of wire and cable accessories available to industry buyers.

• Cable bushings provide protection to a wire or cable as it passes through a penetration. They are similar to a grommet and are inserted into a wall to provide a clean appearance for cable entry. Cable bushings were originally designed for indoor use on sheetrock, but they are now also available for outdoor applications. They are a low cost and easy alternative to installing wall plates but must be sealed with a sealant to ensure that moisture doesn't seep into the opening.

Cable Bushing. Image Credit: Newark

• Cable glands/ cord grips are used in a variety of indoor and outdoor applications to prevent cable pullout and provide strain relief. Like many wire and cable harness accessories, control grips are also designed to prevent the ingress of dirt, moisture, coolants, and corrosive fumes.They are selected based on the specific application they will be used in.

Cord Grip. Image Credit: Integra

• Cable ties and wraps are used to bundle wires and cables together.
• Clamps are used to secure wires and cables in place. There are a variety of clamps available including plastics clamps and threaded metal clamps.
• Clips are used to secure wires and cables in place. Types include J-style, C-style, and U-style, as well aspush-mount and adhesive-mount.
• Heat shrink tubing is heated so that it shrinks to conform to the size and shape of the underlying material. Due to the wide range of uses, there are many different heat shrinkable tubing which each meet the demands of an individual application. Instead of standard approaches to insulation, such as taping or molding in place, tubing, when heated, shrinks to conform to the size and shape of the underlying material making installation fast and easy. Tubing comes in a wide range of sizes, colors, and materials.

How to select heat-shrink tubing.

• Heat shrink caps are used to seal off the end of a wire or cap.
• Romex connectors are specifically designed plastic-sheathed electrical cables used to retain and sometimes seal around romex cable as it enters a junction box or enclosure.

Romex Connector. Image Credit: Alibaba

• Sleeving adds additionalprotection for wires, cables, or hoses. The sleeve slides over the outside diameter,and depending on material,provides protection from abrasion and or high temperatures.
• Spiral wrap is used to protect, bundle, and cover, wire and cable. It is flexible and can be installed and uninstalled without disconnecting the wires.

Spiral wrap. Image Credit: nycoil.com 

• Strain reliefs protect electronic products by absorbing the mechanical stress caused by pushing and pulling. Strain relief protects the lifeline of your electric products by absorbing the forces of push and pull that may be exerted on the flexible wires, cables, or tubing.
• Wire looms, also known as convoluted tubing, are used in a wide-range of applications. The flexible tubing has a split down the side so that a cable bundle can be inserted. Wire looms aid in the organization of wires and cables as well as protecting cables from abrasion and other damage.
• Wire saddles are used for securing wires and cables into place.They differ in terms of size and design.

Wire Saddle. Image Credit: Digi-Key

Materials

Wire and cable harness accessories are made from a variety of materials depending on the specific application. The following list describes common materials of construction.

• Aluminum is a malleable, ductile, light, trivalent, metallic element that has good electrical and thermal conductivity, high reflectivity, and resistance to oxidation.

• Brass comes with good strength, excellent high temperature ductility and reasonable cold ductility, good conductivity, excellent corrosion resistance, good bearing properties, and low magnetic permeability.
• Cloth products arereusable and are often used to bind and organize cables.
• Nylon products are durable, cheap and stronger than natural-fiber ropes.
• Polyester is made from synthesized polymers. It can be used in a variety of applications since it is easy to wash and holds form well. However, care should be taken when using the material because it is highly flammable.
• Polyolefin is a resin that exhibits resistance to chemicals and suitabilityfor a wide range of media.
• Polytetrafluoroethylene (PTFE) - Teflon® is an insoluble compound that exhibits a high degree of chemical resistance and a low coefficient of friction.
• Polyvinyl Chloride (PVC) is a widely used material that has good flexibility, smooth surface properties, and nontoxic qualities. Some grades are used in food and chemical processes due to the inert nature of PVC. Brand names include: ACP® and Dural® (Alpha Gary), Geon® (Geon), Benvic® (Solvay), Flexalloy® (Teknor Apex).

Design Specifications

Design specifications of wire and cable harness accessories include maximum diameter, length, temperature range and mounting size. These are important to consider for determining compatibility.

• Maximum diameter is measured in English units such as inches (in) or metric units such as millimeters (mm) or centimeters (mm).
• Length of the overall cable or wire.
• Temperature range is measured in either degrees Fahrenheit (°F) or degrees Celsius (°C).
• Mounting Size of thread or mounting feature

Features

Wire and cable harnesses can come with a variety of features.

• Conduits guide wires and cables while protecting them from environmental hazards such as chemicals, heat, humidity, and fire.
• Markers are used to label wires, cables, and tubing.

Color-coding band. Image Credit: EZHook

• Weatherproof or water-resistant accessories will protect wiring and cables that are exposed to the elements.
• Breaking strength is impact-resistant and dimensionally stable.

Applications

Wire and cable harness accessories are used in many applications where wiring is prevalent and needs protection and organization.

• Marine environments
• Basements and garages
• Machine shops
• Humid areas
• High-temperature
• High-voltage applications
• Electrical wiring

Standards

There are several approvals for wire and cable harness accessories.

• The Canadian Standards Association (CSA) Mark may appear alone or with indicators. The CSA Mark appears alone when products are certified for the Canadian market according to Canadian standards. The CSA Mark appears with the indicators "C and US" or "NRTL/C" for products that are certified for both the U.S. and Canadian markets.
• Underwriters Laboratories (UL) features the UL Listing Mark.

Resources

Cable Glands

Coax Cable Bushings

What is a Wire Loom?

Wire Loom, Wire Wrap

What is Polyester?

What is a Cable Harness?

• Protection of High-Voltage Power Supplies (HVPSs) in Single and Multiple HVPS Applications
  It is strongly recommended to connect UltraVolt high-voltage power supplies electrically using the proper sockets, either PCB mounted or on a cable harness. Connections can, however, be made by soldering directly to the pins, as long as a few precautions are followed. When soldering to the pins...