Whether routing wires for industrial applications or domestic electrical devices, you need a cable arrangement method that's safe, effective and durable for its purpose. Electrical wires are normally arranged in two main ways: as cable assemblies or as wire harnesses. It's not uncommon for these two terms to be used interchangeably, thus causing further confusion during the wire-arrangement process.
However, a cable assembly and a wire harness are quite different.
Differences between the two
A cable assembly is essentially a group of individual wires bound together to create one thick strand of wire. The individual wires within a cable assembly are often individually insulated to help them retain their function. What defines the cable assembly is a single, thick cover that groups multiple wires into one long strand.
On the other hand, a wire harness consists of distinct cables that are simply tied together by a flexible sheath (or a zip tie). Each wire within a harness retains its distinct insulation and appearance, and they may even be colour-coded for ease of connectivity (think of the cables that are on circuit boards of electronic devices such as computers and mobile phones).
There are certain situations where a wire harness is the preferred option over a cable assembly. Here are 3 of those situations.
1. When routing cables indoors
A wire harness is the best choice when you're grouping cables together for indoor use. They come in handy when you need to wire your home with sockets, outlets for appliances and wiring for light bulbs. This is because a wire harness simply groups distinct wires together using a light outer sheathing. Each individual wire retains accessibility and can be used to connect where it needs to.
2. When you need multiple functions from each wire
As opposed to a cable assembly, a wire harness leaves each individual wire within easy reach. Therefore, the entire harness is easy to access and modify as necessary. You can route individual wires within a harness to connect them to different parts of an electrical device/system.
On the other hand, a cable assembly has its individual wires covered with a tough outer sheath (made of rubber or thermoplastic). Therefore, the grouping of the cables results in only a specific number of connectivity points for the entire assembly (determined by how the cables were routed).
3. When you need a cost-effective option
Wire harnesses are more cost effective than cable assemblies. In fact, a wire harness can be as simple as a zip tie that groups various cables together. The sheathing that holds a wire harness is light, flexible and easy to modify. On the other hand, cable assemblies are often more complex to prepare and thus may cost more.
Contact an electrician in your area for more information.