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This section provides an overview for wire harnesses as well as their applications and principles. Also, please take a look at the list of 14 wire harness manufacturers and their company rankings. Here are the top-ranked wire harness companies as of December, 2024: 1.Omega Leads, Inc., 2.Buckeye Electrical, 3.Molex, LLC.
Table of Contents
A wire harness is a general term for a group of parts that are responsible for the connection between devices and that are bundled together with electric wires, terminals, and connectors attached to both ends of the wires to transmit various electric signals emitted from the devices.
Because multiple electric wires are necessary for the number of signals to be transmitted, and because the thickness and flexibility of the wires vary depending on the intended use and the size of the current flowing through them, they can be compared to "blood vessels" in human terms in terms of their function.
The most typical use of wire harnesses is in automobile wiring harnesses. Wiring harnesses are used around the engine, where the lead-acid batteries and other components that supply electricity to the car are mainly located, as well as around the driver's seat, rear tail lights, and other areas of the car.
Recently, with the widespread use of hybrid and electric vehicles, there is a growing demand for products that are lighter and can withstand higher voltages, and the development of products with particularly high voltage resistance is underway.
Wire harnesses are used to connect devices and equipment to transmit electrical signals from one to the other. Wire harnesses are also used in many other fields besides automobiles. Examples of applications are as follows:
The most typical use of wire harnesses is in automobiles. They are concentrated around the engine, which is the main power source. Starting from the engine periphery, they are connected to all parts of the automobile, including the air conditioner control panel located inside the automobile, and the brakes and rear tail lights located outside the automobile.
For ease of assembly and maintenance, the wiring harnesses are not connected by a single long wire but are divided into sections, such as "front, middle, and rear," and are installed in the car. The connections between the divided wire harnesses are generally made via connectors.
In addition to engine applications, harnesses for sliding doors also exist. Sliding door applications are designed for smaller sizes and mobility.
Harnesses are also used inside medical equipment such as MRIs and CTs. Compared to automotive applications, where the wire harness itself has to pass through the limited space inside the vehicle while considering vibration and water damage, the shape of the wire harness itself is simple.
Instead, the reliability of information between connected devices is required, so the required performance in terms of noise reduction and electrical resistance tends to be high.
Wire harnesses are also used in equipment used to produce electrical appliances and other products. Production lines in factories are long and are expected to be used for a long period, and in some cases, production lines are relocated, so long wire harnesses are often used.
In addition, wire harnesses are often trampled by both workers and heavy machinery in factories, and are often contaminated with oil and dirt, so high durability of wire harnesses tends to be required.
There are different types of wire harnesses, ranging from low-voltage wire harnesses for general applications to high-voltage wire harnesses for high voltage applications.
Low-voltage wire harnesses are used to supply power from the 12V lead-acid batteries used in conventional gasoline-powered vehicles to various components.
High-voltage wire harnesses are wire harnesses for use in electric and hybrid vehicles, which have been in increasing demand in recent years.
Motors are used to drive electric and hybrid vehicles, which require high power output to drive the motors. In addition, the control unique to electric and hybrid vehicles, such as using the motor as a generator during deceleration to charge the battery with regenerative energy to extend the cruising distance, requires higher heat resistance performance to withstand more complex system control.
Therefore, conventional wire harnesses cannot withstand high voltages and large currents, and high-voltage wire harnesses have been developed.
Aluminum wire harnesses are wire harnesses in which the conductor of the wires has been changed from conventional copper to aluminum.
Although it is expected to be 30~40% lighter than conventional copper, it has lower electrical conductivity and lower melting point than copper and thus has issues with heat resistance and the processability of crimp terminals attached to the terminals.
As the number of wire harnesses increases with the improvement of automobile safety and comfort, and with the shift to automated driving, there is concern that the weight of the car body will increase, and the demand for lightweight aluminum wire harnesses is increasing.
Wire harnesses consist mainly of corrugated tubes, clips, connectors, terminals, wires, and tapes.
A corrugated tube is a bellows-shaped tube used as a protective material for wire harnesses. Since it is mainly used to protect electric wires, heat resistance, and shape restoration properties are required.
There are two types, one with slits and the other without slits, for ease of processing during installation, so it is necessary to select one according to the need. Polypropylene resin is often used as a material.
Clips are used to secure wires when crawling wire harnesses. Various types exist according to the size and shape of the harness.
Connectors are used to connect electrical wiring. Generally, male and female connectors come as a set. By crimping dedicated terminals onto stripped wires and inserting them into connectors, connections can be made easily without soldering or twisting wires together.
Terminals are attached to the ends of wires. Like connectors, terminals also come in male and female sets and are used to connect wires by touching the terminals when connecting to a connector.
Generally, wires and terminals are joined by crimping.
Wires are used to supply electric power and transmit electrical signals to connected devices. Copper is mainly used for wires because of its good balance of price and conductivity, but the number of wires used in wire harnesses is expected to increase in the future as systems become more complex. As a result, there is a growing demand for lighter weight wires themselves, and the development of aluminum wires is underway.
Tape is used to restrain electric wires and protect insulated parts. Since wire harnesses require insulation and flame retardance, vinyl tape made of vinyl chloride is mainly used.
The manufacturing of wire harnesses involves many processes that are carried out by hand, so full automation of production is less advanced than in other manufacturing industries. For this reason, production is often carried out in countries with low labor costs, and the ratio of female employees, who are suited to light work, tends to be high.
The future of wire harnesses is expected to shift from conventional wire harnesses to high-voltage wire harnesses for electric vehicles and lightweight aluminum wire harnesses.
*Including some distributors, etc.
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Molex was founded in 1938 with the invention of Molex in 1938 and today is headquartered in Lisle, Illinois, and a subsidiary of Koch Industries. In the 1950s, the company invented the Molex connector which became the standard for power connections in personal computers for decades. Today the company is a manufacturer of electronic and fiber optic connectivity systems for customers in industries such as automotive, consumer electronics, healthcare, manufacturing, and telecom infrastructure. The company has several product categories including Connectors, Optical Solutions, Capillary Tubing & Micro Components, and Automation.
Omega Leads, Inc. is a custom cable assembly manufacturer and supplier. It is headquartered in Santa Monica, California, and was established in 1961. The company manufactures a wide range of custom cable assemblies, including power cables, signal cables, and control cables. Some of its popular products are custom wire harnesses, data cables, and fiber optic cables. Omega Leads also provides value-added services, such as wire marking, Cable Assemblies, Wire Harnesses, Wire Identification, Crimp Capabilities and cable testing. Its products are used in various industries, including aerospace, medical, and industrial automation.
Buckeye Electrical was founded in 1995 and is a manufacturer of electronic products based in Botkins, Ohio, United States. The company manufactures various electrical products such as wire harnesses, coil winding, and cable assemblies. These products have been used in various applications in industries such as military, medical, and recreational. The company offers various other supporting services such as reverse engineering, ultrasonic welding, and electrical testing. Customers can send requests the company for specific quotes and custom products according to specific requirements.
Cypress Industries, founded in 2001, as a global contract manufacturer of custom cable assemblies and wire harnesses, custom control panels, plastic injection molding, machining, and metal castings that operates as a vertically-integrated company. Established as a contract manufacturer, Cypress Industries specializes in providing diverse manufacturing services across its facilities in Austin, Texas, Mexico, India, and China. The company's capabilities span printed circuit board assemblies and sheet metal fabrication, making them a comprehensive manufacturing partner. With quality, Cypress Industries serves as a go-to source for manufacturing solutions tailored to clients' specific needs.
Co-Operative Industries Aerospace & Defense was established in 1946 and is a manufacturer and supplier of electrical harness, cable, and interconnect solutions based in Fort Worth, Texas, United States. The company manufactures various products such as flexible conduit assemblies, high tension ignition leads, and rigid lead assemblies. These products have been used in various applications such as aerospace, industrial engines, and automated manufacturing industries. The company has been certified in FAA, EASA, and CAAC certification and has been registered in AS9100 and ITAR.
Precision Cable Assemblies was founded in 1980 and is a manufacturer and supplier of wire harnesses, battery cables, and custom wiring solutions headquartered in Brookfield, US. PCA produces custom engine harnesses and battery cable assemblies for various applications, including outdoor power, recreational vehicles, marine, generator sets, and appliances. It also provides services for prototype development, design, and full production, along with 100% documented continuity testing. The company adheres to ISO 9001 and ISO/TS 16949 quality management and serves OEMs across the world.
Y.C. Cable is a manufacturer and supplier of custom cable and wire harnesses established in 1985 and headquartered in Silicon Valley, California. The company offers cable assemblies such as ethernet, custom robotic, USB C, copper, and custom battery cable assemblies used in power and data transmission. The company is IPC-620-compliant, ISO, and TS16949-certified and offers custom cable assemblies and wire harness assemblies for various industries, including aerospace, consumer electronics, automotive, medical, and industrial.
Yazaki Corporation is a Japanese manufacturer of wire harnesses and related products that was established in Tokyo in 1929. The company’s product lineup includes a wide range of wire harnesses, connectors and terminals, and display equipment for monitoring crucial information such as fuel level or engine temperature. It also offers optical fibers, electric wires, and solar equipment. The company’s products are commonly used by its clients in the gas, automotive, telecom, and construction industries.
Amphenol Interconnect Products Corp. (AIPC), founded in 1932 and located in Endwell, New York, is a designer and manufacturer of electro-mechanical cable assemblies and Value-Add Interconnect Solutions. The company offers a range of products that include cable assemblies, backplane assemblies, power solutions, integration, and wire harnesses. These products have diverse applications across industries such as telecommunications, aerospace, automotive, and medical devices. The company’s products enable electrical connections, data transmission, and power distribution in systems and equipment, providing effective performance in a range of applications.
Volex is a manufacturer and supplier of power cords and cable assembly solutions founded in 1892 and headquartered in Hampshire, UK. The company mainly produces power cords, plugs, connectors, and receptacles. It also offers integrated manufacturing services, including PCB assembly, box build, and complex cable assemblies. The company has 19 manufacturing facilities across 22 countries with a global workforce of over 8,000 employees. It serves a diverse range of markets, such as consumer electronics, medical equipment, telecommunications, industrial robotics, and the automotive sector.
Dongguan XSD Cable Technology Co. Ltd. was established in 2013 and is a manufacturer and supplier of a wide range of cables and wires headquartered in Guangdong, China. The company mainly produces wiring harnesses, cable assembly, audio and video cables, ethernet cables, and USB data cables. It also provides custom wire and cable solutions, offering various options like multi-conductor, multi-pair, instrumentation, power, and portable cables to meet client needs. The company holds UL, CSA, CCC, ISO 9001, and IATF 16949 certifications, serving the needs of new energy, industrial, automotive, home appliance, and communication industries.
Sumitomo Electric Industries Ltd. is an ISO 45001-certified manufacturer of optical fiber and electrical wire cables that was established in Osaka, Japan, in 1897. The company produces optical fiber products for data communication or telecom applications, wire cable products for power transmission and automotive electronics, and flexible printed circuits for electronic device assembly. It also offers compound semiconductors for use in optical and wireless communication. The company’s products are commonly used by clients in the aerospace, telecommunications, and consumer electronics industries.
Ranking as of December 2024
Derivation Method| Rank | Company | Click Share |
|---|---|---|
| 1 | Omega Leads, Inc. |
18.1%
|
| 2 | Buckeye Electrical |
12.2%
|
| 3 | Molex, LLC |
11.5%
|
| 4 | Precision Cable Assemblies |
10.5%
|
| 5 | Cypress Industries |
8.0%
|
| 6 | Belden Inc. |
7.8%
|
| 7 | Co-Operative Industries Aerospace & Defense |
6.8%
|
| 8 | Y.C. Cable |
6.2%
|
| 9 | Yazaki Corporation |
5.3%
|
| 10 | Volex plc. |
4.7%
|
Derivation Method
The ranking is calculated based on the click share within the wire harness page as of December 2024. Click share is defined as the total number of clicks for all companies during the period divided by the number of clicks for each company.Number of Employees
Newly Established Company
Company with a History
*Including some distributors, etc.
*Including some distributors, etc.
| Country | Number of Companies | Share (%) |
|---|---|---|
|
United States of America
|
8 | 66.7% |
|
Japan
|
2 | 16.7% |
|
United Kingdom
|
1 | 8.3% |
|
China
|
1 | 8.3% |
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