Wire or cable details
- Length, including the tolerances needed in your application
- Wire color(s)
- AWG (clearly note if you are using a mix of wire gages)
- Properties
- Stranding/ wire count
- Insulation type
- Necessary Agency Rating and requirements (UL, CSA, USCAR etc.)
- Breakdown voltage
- Temperature requirements
- Copper wire or Tin Copper
- Any unique requirements specific to the assembly
Termination Details
- Type of termination
- Terminal
- Strip and retain
- Blunt cut wire
- Tinning
- Connector housing part number
- Terminal part numbers
- Confirm specified housing and terminals work for identified wire type
- Validate component operating temperature meets or exceeds requirements
- Pinout of wiring (clearly noting location of pin 1 and wire colors if used)
- Length requirements of branches between the connector and wire end
- Any advantage or need to have the harness manufacturer use ultrasonic welding
Harness Finishing Requirements
- Concerns for abrasion
- Labeling
- Ties, taping, straps, lacing, sleeves, or conduit
- Branching
- Any necessary retainers or seals
- Heat shrink (single or dual wall)
- Addition of a sleeve
- Braiding
- Shielding
- Twisting of wires
- Molding
- Any special considerations for routing and/or protecting the harness
Quality Considerations
- Use polarized connections
- Including terminal retainers into your design can make it more robust
- Confirm sufficient room in the application for wire bundles to run without interfering with other components
- Validate wires are long enough, yet not an excessive length (you do not want the wires too tight)
- Large bundles need to be long enough to accommodate any bend radius
- Request a Terminal Crimp Process Verification Report from your supplier to show crimp cross sections, wire/ terminal compatibility and SPC detail insure your supplier meets Industry Standards – also note if additional standards are required
