Wire Harness Estimator Components Defined


Our New Wire Harness Estimator

Falconer Electronics, Inc recently announced a new tool, The Wire Harness Estimator, to assist with determining the cost of a Wire Harness Assembly. You can check out our estimator here.

The Wire Harness Estimator allows you to quickly and easily enter the components that make up your wire harness and within seconds you will receive an email with the estimate.

Below you will find helpful definitions as a guide to use the Wire Harness Estimator.

Wire Types And Their Uses

Stranded: When a wire needs to be flexible in a product.

Flexible Ground Braid: Grounding connection between two terminals while still having the ability to move or vibrate.

Ribbon Cable – Gray: Usually used to make connections between electrical devices such as computers, DVD players, or hard drives.

THHN – Solid: For a fixed application like traveling through a straight formed conduit.

THHN – Stranded: For an application where there is a need for flexible wire. As when placing wire around corners or in power boxes.

Wire Gauges And How They Are Defined

Wire Gauges We Offer:

22, 20, 18, 16, 14, 12, 10, 8, 6

Physical Size of Wire:

The physical size of a wire is defined by the number of operations that it takes to get it to that physical size. This process means that a 22 gauge wire is much smaller in size than a 6 gauge wire.

The smaller the wire gauge the less current that is traveling through the wire itself. Also meaning the smaller gauged wires have less amperage they can handle.

Wire Colors And Their Uses

Black: Hot/ Positive

White: Common/ Negative

Green: Ground

Red: Secondary Line: Hot/Positive

Blue, Yellow, Brown: Available for customer’s personal choice to connect one point to another.

Terminal Types And Their Purposes

Ring Terminal: To connect two points through a wire and is attached with a screw.

Fork Terminal: Much like that Ring Terminal it connects two points through a wire and is attached with a screw. However, it is also useful if you need to remove the terminal from a device because of its open-ended design.

Quick Connect / Disconnect Terminal: Terminals that attach to another terminal by sliding into place. There are female and male connecting terminals.

Ferrule Terminal: Fastening, joining, sealing, or reinforcing wires to each other. Also has many different applications due to the many different types there are.

    Terminal Insulation Type And Their Purposes


  • Partially Insulated- Usually on ring or fork terminals. Used mostly to prevent crossing/ shorting of the wires by preventing contact with other wires.
  • Fully Insulated- Mostly on Quick Connect/ Disconnect terminals. The purpose of fully insulated terminals is to prevent contact between terminals. Therefore, the wires would not be in contact with each other in small spaces.


Terminals that need to be crimped in place or soldered in place. Are also, usually finished with heat shrink tubing.

Terminal Stud Sizes And Why It’s Important To Know What Size You Need 

Terminal Stud Sizes We Offer:

2,4,6,8,10, 1/4″

Why is the terminal stud size important:

If your assembly requires attachment of wires by screws or other hardware you need to be sure that you have a proper size to fit the hardware you are using.

Therefore, if you are using a 1/4″ screw in your assembly but you have a #2 terminal stud it will be impossible to attach your wire to your assembly.

The other important thing to remember when looking at terminal stud size is they have to be able to fit your screw or hardware. This means that a 1/4″ terminal stud will actually be slightly larger than a 1/4″.

Wire Harness Add-Ons And Their Uses

Spiral Wrap: Bundles wires together while still providing flexibility

Wire Ties: Bundling wires into separate groups, separating wires from other wires in the harness, also, holding a wire into a specific direction

Shrink Tubing: Protecting and insulating wire from outside elements

Contact Us

For more information on our wire harnesses check out our Wire Harness page.

For additional information on the Wire Harness Assembly Process, please click the links below:

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