GUIDELINES TO PREPARE WIRING

HARNESS FOR TWO WHEELERS.

OMKAR ANAND JOSHI

INTRODUCTION
WHAT IS WIRING HARNESS ??
A wire harness, also known as cable assembly, wiring assembly or wiring loom, is
an assembly of electrical cables or wires which transmit signals or electrical power.

The cables are bound together by straps, cable ties, sleeves, electrical tape, conduit,
or a combination thereof.

By binding the many wires and cables into a cable harness, the wires and cables can
be better secured against the adverse effects of vibrations, abrasions, and moisture.

By constricting the wires into a non-flexing bundle, usage of space is optimized,

and the risk of a short is decreased.
STAGES IN MAKING A WIRING HARNESS

1 2 3 4 5
Specifying the Making a Connector Insulation and Testing
characteristics wiring ,crimps and safety
diagram joints
 SPECIFYING THE CHARACTERISTICS

In order to suit their specific requirements, clients will provide a set of characteristics they
would need in the finished product.

Specifications will be provided on conductor sizes, conductor type, insulation material, etc.
and manufacturers have to produce accordingly.

Also, certain transmission outcomes are desired and in order to achieve them, manufacturers
must truly understand the purpose of the harness and characteristics required to achieve that.
 CONDUCTOR TYPES AND SIZES

A conductor is an object or type of material (metal) that allows the flow of an electrical
current in one or more directions.
A conductor in the form of flexible strand or rod with a insulation is called a wire.
Wire with more than one strand is called as Multi strand wire and more correctly called as
CABLE
Wire comes in solid core, stranded forms.
TYPES OF WIRES

SOLID CORE WIRE OR STRANDED WIRE OR MULTI

SINGLE STRAND WIRE STRAND WIRE
 SINGLE STRAND WIRE MULTISTRAND WIRE
Single strand wire, also called solid-core Stranded wire is composed of many pieces of
wire, consists of one single piece of metal solid strands all bundled into one group.
strand

Solid wire is the wire of choice for
outdoor or rugged-duty applications which
may expose the wire to corrosive
elements, adverse weather condition or
infrequent movement.
Stranded wire, conversely, serves a better purpose
in intricate usages, such as electronic devices and
circuit boards, where the wire will be protected
but may undergo bending or twisting in order to
connect electronic components.

The advantage of solid wire is one of cost, On the other hand, stranded wire has more
simplicity and durability. Because it is manufacturing cost but will last longer
merely a single, thick strand of wire, the
wire is very resistant to damage and
extremely simple to make.
The total surface area is surface area of the The total surface area is equal to the sum of
single solid strand for a given AWG surface area of all the strands for same AWG

A STRANDED WIRE WITH THE SAME CROSS-SECTION OF CONDUCTOR AS A SOLID WIRE IS

SAID TO HAVE THE SAME EQUIVALENT GAUGE AND IS ALWAYS A LARGER DIAMETER.
 SINGLE CORE MULTI CORE

A single core wire is a single wire which Multi core cables are cables, which
can be solid core or stranded contains more than one core in the cable.

They are mainly used in electrical home Multicore wires or cables are widely used
appliances since these wires can take a for industrial purpose ,entertainment
good load sector etc

Single core cables are very high ambient multicore cables can be used anywhere
wires; these cables are a good conductor that might benefit from combining data,
of electricity as well as heat. These cannot power, coaxial and AV cores into a single
melt or burn easily. cable

Lighter in weight and more flexible More in weight and less flexible
SINGLE CORE MULTI STRAND MULTI CORE MULTI STRAND
AMERICAN WIRE GAUGE
American wire gauge (AWG), is a standardized wire gauge system used since 1857
predominantly in North America for the diameters of round, solid, nonferrous, electrically
conducting wire.
The cross-sectional area of each gauge is an important factor for determining its current-
carrying capacity.
Increasing gauge numbers denote decreasing wire diameters
The AWG tables are for a single, solid, round conductor. The AWG of a stranded wire is
determined by the cross-sectional area of the equivalent solid conductor.
Because there are also small gaps between the strands, a stranded wire will always have a
slightly larger overall diameter than a solid wire with the same AWG.
The diameter of a No. n AWG wire is determined by following formula

Alternatively AWG n can be calculated from diameter using following formula

Area of cross section can be calculated using following formula

RULES OF THUMB

1.When the cross-sectional area of a wire is doubled, the AWG will decrease by 3. This
doubles the ampacity.
2. When the diameter of a wire is doubled, the AWG will decrease by 6. This quadruples the
cross-sectional area and the ampacity.
3. A decrease of ten gauge numbers, for example from No. 12 to No. 2, multiplies the area and
weight by approximately 10, and reduces the electrical resistance (and increases the
conductance) by a factor of approximately 10.
4.Sizes with multiple zeros are successively larger than No 0
Eg: AWG 0000 is denoted as 4/0
The power drop, or power lost in a cable, depends on the cable length, cable size and the
current through the cable.
Larger cables have less resistance and can therefore transmit more power without large
losses.
Losses in smaller cables remain low if the amount of power transmitted is small, or if the
cable is not very long.
Electric cables have a resistance per foot, and the longer the cable, the larger the resistance.
Larger diameter cables have less resistance per foot than smaller cables.
The power lost in watts is determined by the voltage drop , which is calculated by using
simple ohms law :V=I*R.
Then power is calculated using P=V*I
 WIRING DIAGRAM

A wiring diagram is a simple visual representation of the physical connections and physical
layout of an electrical system or circuit.
It shows how the electrical wires are interconnected and can also show where fixtures and
components may be connected to the system.
Wiring diagrams are made up of two things: symbols that represent the components in the
circuit, and lines that represent the connections between them.
Place the components such that there are less wire crossings.
TINY CAD
CONNECTORS ,TERMINALS AND JOINTS
An electrical connector, is an electro-mechanical device used to join electrical terminations
and create an electrical circuit.

Electrical connectors consist of plugs (male-ended) and jacks (female-ended). The

connection may be temporary, as for portable equipment, require a tool for assembly and
removal, or serve as a permanent electrical joint between two wires or devices.

Connectors may join two lengths of flexible copper wire or cable, or connect a wire or cable
to an electrical terminal.
 TYPES OF SPLICE
BUTT CONNECTOR
CONNECTORS
CONNECTOR BULLET CONNECTOR PUSH ON CONNECTOR

Insulation: VINYL Insulation: POLY PROPELENE Insulation : VINYL Insulation : VINYL

Material: BRASS WITH TIN Material : BRASS WITH TIN Material :BRASS WITH TIN Material :BRASS WITH TIN
PLATED PLATED PLATED PLATED
MAXIMUM ELECTRICAL MAXIMUM ELECTRICAL MAXIMUM ELECTRICAL MAXIMUM ELECTRICAL
RATING: 75C 300 VOLTS RATING: 105C 600 VOLTS RATING: 75C 600 VOLTS RATING: 75C 300 VOLTS
MAX. MAX MAX. MAX

Wire Gauge: BLUE:16-14 Wire Gauge: BLUE:16-14 Wire Gauge: BLUE:16-14 Wire Gauge: BLUE:16-14
RED:22-18 RED:22-18 RED:22-18 RED:22-18
YELLOW:12-10 YELLOW:12-10 YELLOW:12-10 YELLOW:12-10
TERMINALS
RING TERMINALS SPADE TERMINALS PIN TERMINALS

non-insulated, vinyl insulated, vinyl insulated, nylon insulated, vinyl insulated, nylon insulated,
nylon insulated, nylon insulated nylon insulated with an extra nylon insulated with an extra
with an extra sleeve or heat shrink sleeve or heat shrink insulated sleeve or heat shrink insulated
insulated types. types. types.

R:22-18, B:16-14 and Y:12-10 R:22-18, B:16-14 and Y:12-10 R:22-18, B:16-14 and Y:12-10
gauge sizes. gauge sizes. gauge sizes.

MAX ELECTRICAL RATING:105C MAXIMUM ELECTRICAL RATING: MAXIMUM ELECTRICAL

600 VOLTS MAX. 105C 600 VOLTS MAX. RATING:75C 600 VOLTS MAX.
TYPES OF PLATING
Contact terminals and crimps are often plated with gold ,silver ,tin, etc
Copper will form a layer of oxide or other tarnish through normal exposure to the elements
that will eventually increase the contact resistance of two mating copper contacts, rendering
the connection faulty.
The best metal for this purpose is silver (Ag). It has the highest conductivity, even better than
copper and much better than gold.
The weakness of silver coated connectors is that they are very sensitive to sulphur (S)
compounds, which are present in human sweat (even its vapour) and breath, which produce
the worst kind of patina which you can find on silver contacts.
Gold (Au) has worse conductivity than silver (still very good) but is free from the above
drawbacks, no corrosion at all, produces no patina.
In low cost applications ,copper plated with tin is used . Tin is not as good as gold in the
corrosion resistance department, but it is better than copper, and cheaper than gold.
ELECTRICAL JOINTS

There are a variety of cable jointing techniques.

The joints can made through twisting the wires, or using
mechanical connectors such as crimps.
Some of the cable joining techniques are as follows:
WESTERN UNION SPLICE.
RATTAIL JOINT
FIXTURE JOINT
KNOTTED TAP JOINT
FIXTURE JOINT KNOTTED TAP JOINT