In general applications, such as automotive, outdoor LED screens, agricultural, construction machinery, etc., there are in rainy environments, the waterproof harness performance is very critical. Now we introduce the key points of waterproof wiring harness process

1.    Select high reliability waterproof connector

The key point of waterproofing for the entire cable is where it breaks: the connector place. In all case, water can not be penetrated between the plug and socket and wet the contacts, otherwise it will cause a short circuit. it is necessary for the connector to provide a safe and reliable connection. Select the authority connector manufacturers with excellent processing control and precision assembly equipment and multiple performance testin. According to the specific application, select the corresponding IP protection level of the connector.

2.    Cable Harness Design

An industrial cable harness consists of low-voltage cables and wires that connect different electrical devices. It is like the nervous system of your equipment and you need to make sure it is well protected and stable to keep your equipment running. An industrial cable harness consists of low-voltage cables and wires that connect different electrical devices. It is like the nervous system of your equipment and you need to make sure it is well protected and stable to keep your equipment running, You need to choose water-resistant cables wherever the cable may be exposed to moisture. Usually the environment in which it is used is not pure water, so usually the cable also needs to be resistant to corrosion and salt spray. Automotive cable harness design needs to be divided into areas. When designing the electrical system, it is necessary to refer to the water depth of the whole vehicle so that key electrical components are arranged above the “water line”. At the same time, electrical components below the “wading line” can be effectively waterproofed.

3.    Production process

Waterproof cable harness production is the same as the general cable harness process, there are some points to note, waterproof terminals must be crimped using a special crimping tooling. Wire harness inner connection points and joints are sealed, solder points and wiring points are protected by heat shrink tube. the wire harness welding point must be also protected by heat shrink tube. Copper wire must not pierce the heat-shrink tube, heat-shrink tube must be all covered copper wire

4.    Airtightness testing

Waterproof harness testing is carried out by gas tightness testing equipment, using compressed clean air such for gas tightness testing, this equipment can simulate the test environment of 10 meters – 100 meters underwater, with parameter pressure in the range of 0.1Mpa-1.0Mpa. The two ends of the harness are connected to the equipment, fed with compressed air and pressure tested to verify whether the sealing performance is passed. The factory will test the electrical performance, sealing performance and check appearance.

Strict waterproof harness design, procurement of high quality waterproof cable materials, manufacturing according to strict cable assembly process and intensive quality inspection, we can produce qualified waterproof cable harnesses.