Aircraft Wiring Harness - Aircraft and the aviation sector, as it exists now, would not exist without the technological breakthroughs it has experienced. At the same time, an aircraft wire harness serves the same primary function as any other wiring system, Innovations it has brought to the Aerospace industry.
Custom manufacturer of high and low voltage wire harnesses. Features include electrical tapes, binding clamps, sleeves and abrasion, heat, oil and water resistance. Additional capabilities such as automated cable testing, circuit card assembly (CCA), consultation, tooling design, Electromechanical assembly, fabrication and installation are provided.
Aircraft Wiring Harness
Prototype and medium to low volume production offered. Serves the aerospace, defense, automotive, transportation, heavy equipment and electronics industries. Meets ASTM and AS standards. NSF and GSA approved. IPC-A-610, IPC J-STD-001 and IPC/WHMA-A-620 certified. Custom manufacturer of cable assemblies, wire harnesses and molded components.
Managing Complexity In Aerospace Wire Harness Design
RF, ribbon, jacketed, electro-mechanical and twisted cable assemblies are available. Serves the aerospace, electronics, transportation, technology, medical, healthcare and military industries. Some cable assemblies meet military specifications. ISO 9001:2015 and ISO 13485:2016 custom manufacturer of complex electric wiring harnesses for the aerospace, agricultural, automotive, computer, construction, firefighting equipment, grinding technology, material handling, medical, military, motorcycle, telecommunication, transportation, and other industries
. Prototype and low to high volume production offered. REACH compliant. On-time delivery. 12-month warranty. The aircraft wire harness is based on different wires and connectors. Moreover, other standards, non-standard, and COTS parts make the harness complete and functioning.
While choosing the elements, you need to look into your requirements. Then you will get to design the schematic using CAD software. Here at Cloom, we offer wiring harnesses and cable assemblies to make your connection safe and reliable.
Managing complexity in Aerospace wire harness design is possible with the use of modern electrical design tools that support real-time, interactive design checks and preliminary analysis. It is not uncommon to have a tenfold growth in the electrical content for new platforms in Aerospace and defense programs.
Key Elements Of Aircraft Wire Harness Development
This creates an unwieldy situation. When the design is completed, the quantity of unique component part numbers can rise to several hundred and be repeated thousands of times throughout the harness system. The ability to manage this is critical to the overall success and modern design tools provide increasing value.
Custom manufacturer wire harnesses. Components such as Shrink tubing, non-shrink tubing, lacing, cable ties, bread ties and spiral wrap offered for protection of harness. Capable of building harness with various wire, cable or combination including PVC or PTFE insulation, multi-conductor cable or coaxial cable.
Suitable for commercial applications and for integrating other electronic components such as PCB's, resistors, motors. Serves the medical instrumentation, military, government, power generation and water and wastewater treatment industries. Blanket orders accepted. Pull-system capable. Meets IPC/WHMA-A-620 and IPC J-STD-001 standards.
CSA approved. ITAR registered. RoHS compliant. UL listed. Kanban and JIT delivery. Made in the USA. Electrical system design and integration are contributing to a "harnessing" of great potential in the Aerospace and defense industry. It is time to embrace all the change and performance that state-of-the-art wire harness systems engineering will bring.
Aerospace Wire Harness Design
Custom manufacturer of electrical wiring harness assemblies. Lead assemblies and braided harnesses can be fabricated. Soldering, overmolding, brazing, milling, lathe machining, vertical milling and wire EDM machining services are available. Contract manufacturing is available. RoHS compliant.
UL® and CSA® certified. We are the sole licensee of Lockheed Martin for F-16 electrical products. Through this agreement, we have access to Lockheed Martin's F-16 engineering data, tooling and configuration control information. We also have a Technical Services agreement with Sikorsky for all of their aircraft.
This agreement allows us to obtain their engineering data needed to rewire helicopters that Sikorsky manufactures. This paper discusses key elements of aircraft wire harness development in an environment of increased complexity, including planning, design of harness content and installation considerations.
Advanced E/E system design tools and methodologies are included as critical components for success. Original Equipment Manufacturers also have the option to permit which of their suppliers to produce non-standard components. However, the cost of a non-standard element for an airplane harness tends to be higher since so few of them exist.
Commercial Off-The-Shelf Components Cots
ISO 9001:2015 and AS9100D certified custom manufacturer of electrical wiring harness for aircraft and aircraft engine applications. Products fabricated also include machinery, machined parts, control cabinets, assemblies and components. Capabilities include CNC Precision machining, welding, panel wiring, reverse engineering and machine repair/rebuilding/refurbishing.
InterConnect has worked on a wide variety of aircraft since its founding in 1993. We have manufactured entire ship sets of harnesses for the Sikorsky H-92, which has 261 wiring harnesses. For the USAF F-15C/D EPDS Program, we assembled all of the 170 wiring harnesses and 20 electrical circuit breaker panels and matrix assemblies for each of the 73 aircraft.
For the US Army National Guard UH-60 Black Hawk Rewire Program InterConnect manufactured 24 complete ship sets of 305 wiring harnesses and panels each, prior to installing them into the aircraft here in Fort Worth. Most recently InterConnect Wiring has designed and manufactured 101 wiring harnesses for each Iomax Archangel.
Manufacturer's representative for wire and cable assemblies, linear actuators, terminal blocks, blowers, fans, offshore cables, molded protective cases, covers, holsters, printed circuit boards (PCB), temperature controllers, enclosures, industrial gearmotors, wire harnesses, ignition/power systems, interconnect devices, acceleration switches, load cell/pressure sensors, telescopic slides, linear rails, thermoplastic products and motorized valves.
Standard Components
Sheet metal machining, CNC Swiss screw machining and electronic manufacturing services are also available. The design process is challenging, placing significant pressure on the overall program schedule and budget, particularly on the harness team. Understanding the Fundamentals and key factors of the development process and accounting for inevitable iterations during the design maturation in program planning can help establish a path to success.
Custom manufacturer of aircraft wiring harnesses. Prototype, low, medium to high volume production can be done. Suitable for vehicles, satellites, avionics, inter-shelter communications and high and low voltage applications. Assemblies are used at high altitudes, harsh environments, war zones and in a wide range of temperatures.
Vendor managed inventory (VMI) programs and turnkey system integration services available. RoHS compliant. ITAR registered. UL listed. Meets IPC/WHMA-A-620 Class III and MIL-STD-454 specs. JIT and Kanban delivery. The wire harness and its associated systems are part of an exciting ride into the future.
Although wiring may not be a topic that first comes to mind when imagining future innovations in aerospace, wire harness design continues to be an unseen or unappreciated item that will control and power those very systems being imagined.
Aircraft Wiring And Connection
Subsequently, other Architects came along and incorporated even more electrical infrastructures. Aircraft Mechanics eventually realized that they were installing cables one at a time despite groups of wires flowing from one part to another. Moreover, they needed more wires for each additional device.
Custom manufacturer of electrical wiring and wire harnesses. Computerized testing and complete product re-design services are also offered. Prototype to full production runs. Value added services include Ultrasonic wire welding and low pressure Molding services utilizing Macromelt ® polyamide thermoplastic Molding materials to waterproof connectors, as well as add strain relief.
Suitable for OEM industries such as medical equipment and devices, industrial equipment, semiconductor equipment, telecommunication, automotive, green energy, automation, military and aerospace. Today's aircraft manufacturers must also stay up with rapidly developing technologies and upgraded aircraft wiring connections that can support cutting-edge additions.
In addition to improving efficiency in production and manufacturing, an aircraft wire harness also makes it easier for mechanics to identify and repair planes experiencing technical difficulties. If you are in need of help with a wiring harness or an entire aircraft's worth of electrical system, please contact InterConnect Wiring.
The Functionality Of An Aircraft Wiring Harness
InterConnect specializes in fast turnaround, saving "behind schedule" projects, and in developmental programs. If you have such a need, please contact us or request a quote. Manufacturers mass-produce COTS components in response to market research and consumer demand.
The producer can improve the design of the components without permission from the government or the defense. A manufacturer can create their parts and assign them unique part numbers. Wire assembly, wire processing, OEM contract kitting, packaging & fulfillment of electronic component wiring harnesses for aircraft, electric and electronic industries.
Capabilities include wire harness assembly, soldering and lead tinning. Additional services include inspection and testing. Various applications include welders, gauges, heaters, lighting fixtures, motors and refrigeration equipment. Vendor Managed Inventory (VMI) programs available. Meets IPC standards.
WHMA/IPC A620 certified. UL recognized. JIT and Kan Ban delivery. Metal cables soon replaced the ropes; even today, many planes don't "fly by wire," instead relying on cables and pulleys. Eventually, an airplane designer decided to wire in a light, so he put in a switch, battery, and bulb.
Why Do Aircrafts Have Wiring Harnesses?
They connected these parts with cables, creating the airplane's first electrical lighting system. Since this system only requires a small number of wires, harness manufacturers put them individually in safe locations. AS9100D and ISO 9001:2015 certified custom manufacturer of electrical harness assemblies for the electromechanical, aerospace, and automotive industries.
Using solid or stranded wire, in 40 to 4/0 AWG, assemblies can be terminated with military, commercial, D-Sub, IEC, or crimped connectors. Capabilities include wire cutting and stripping, cable harnesses, wire harness testing and verification. Secondary operations include assembly, machining, bending, forming, welding and quick turn prototypes.
Prototype to large production scale runs. Any new program development begins with balancing competing goals, such as design objectives, build costs and flight-test schedules. Customer satisfaction, performance characteristics and operating costs that provide positive market differentiation are equally important.
Attempting to satisfy these goals requires an intricate balancing act throughout the entire process and eventual Type Certification of the aircraft. Understanding, planning and preparing for the inevitable helps to level-set expectations and helps teams remain focused as they move through the challenges to come.
Three Categories Of Parts In An Aircraft Wiring Harness
The use of digitized technologies, such as the digital twin, are becoming commonplace. The electrical designer's tools require more governing authority in managing things like harness route paths, installation and support requirements, signal types allowed, voltage drop analysis, current and load analysis, safety analysis and material choices dependent upon the environment.
Now more than ever, advanced aircraft E/E system development requires a connected design tool that can grow its capabilities along with the data it manages. Precision CNC machining and fabrication services for metals. Capabilities include welding and assembly.
Also, a contract manufacturer of wire harnesses, weldments and complex assemblies. Long production runs are available. Serves the automotive, defense, aerospace, electronics, renewable energy and high-tech industries. Insulating materials used to be a one-size-fits-all affair, but nowadays, many options are available to meet various needs.
The signal you send and the system's electricity dictate which wires are used. Wire insulation also shifts with these variables. Most aircraft range between 100-400 wiring harnesses. This can vary based on aircraft type, model, and general design.
Advanced Aircraft E/E System Development
If an aircraft is retrofitted with all the "Bells and Whistles" so to speak, it can easily have upwards of 400 harnesses. Woman-owned. ISO 9001:2008 certified. Custom manufacturer of aircraft and electrical wiring harnesses. Various other products available include connectors, contacts, cables, cable assemblies, enclosures and connector accessories.
Prototype and short to long run Productions offered. ITAR registered. JIT delivery. Custom fabricator of wiring harnesses for aircraft & military applications. Fire retardant tanks, terminals, connectors, receptacles, wires & assemblies are also available. Various materials include aluminum, stainless steel & steel.
Capabilities include turnkey assembly, Precision machining & repair. FAA certified. In a plane's electrical system, the military will often have the final say over the components known as MIL-SPEC (military standard). The letters M or MS appended to the beginning of the serial number designate them as a military issue.
Some are prefixed with the letters NAS to show that they conform to the National Aerospace Standard. Aircraft wire harnesses have wiring that is miles long. Therefore you need to plan them precisely and structure them to prevent problems during and after construction.
Innovations In Aircraft Technology
Thus, the first step in any design process is the creation of a schematic in CAD software. It serves as a guide for subsequent construction.
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