The History of Wire Harnesses

Wire Harnesses

Wire Harnesses are an assembly of cables or wires that distribute electrical signals in the most efficient way possible. Cables and Wire Harnesses are bound together by straps, cable ties, cable lacing, sleeves, electrical tape, conduit, a weave of extruded string, or a combination.

In the 1920s, wire harnesses became more prominent, especially in the automotive industry. Engineers found that binding the many wires and cables into a wire harness allowed the wires and cables to be better secured against the adverse effects of vibrations, abrasions, and moisture. The 1920s also saw a boom in electrical household goods. Washing machines, Irons, fridges, vacuum cleaners all designed using many small components and connected by complex individual wiring systems. Manufacturing these products for mass production was often a timely and a costly process and by introducing pre-assembled wire harnesses, manufacturers offered a timelier more cost effective build.

           Wire Harness Assembly

Engineers design Wire Harnesses according to specific electrical requirements. A diagram is then provided for the assembly. Wire harnesses continue to be manufactured by hand, due to the many different processes involved, such as:

  • Routing wires through sleeves
  • Taping with fabric tape, in particular on branch outs from wire strands
  • Crimping terminals onto wires, particularly for so-called multiple crimps (more than one wire into one terminal)
  • Inserting one sleeve into another
  • Fastening strands with tape, clamps or cable ties

Falconer Electronics has been making wire harnesses since 1985. They are a crucial part of any electrical component.  For more information check out our Website!

To learn more about Ground Straps and the Wire Harness Assembly process, please click on the links below:

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