The terminals are packaged in reels, ideal for pneumatic or hydraulic automation tools in wire harness manufacturing.
Another change in wire harness manufacturing is the phasing out of solder and tin-based components, such as connectors with solder lugs. As regulators in the U.S. and many other countries impose stricter restrictions on lead-containing materials, wire harness manufacturers have followed suit, phasing out the use of tin-plated terminals and assemblies that require soldering.
Components such as fully insulated quick disconnects eliminate the need for soldered connections in many harness applications.
Maintain wire strength in signal applications
An ongoing challenge for wire harness manufacturers comes from industry pressure to reduce wiring size and weight. With the increasing use of data-driven applications and components in modern vehicles, there is a corresponding expectation for thinner, lighter wires in wire harnesses. Communication lines can run efficiently on wires as thin as 22 or even 26 gauge. However, this poses problems for heavy vehicles due to vibration issues and the possibility of wire breakage.
But many OEMs have required multiple suppliers to design their components using 18- or 20-gauge wire, even though the signal can be efficiently carried over the thinner wire. OEMs need stronger wires for the physical integrity of the system, and thicker wires for better manufacturability – sonic welding can be done instead of mechanical hinge points that create fatigue points on the wire harness.