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The wire harness is an important, yet possibly overlooked, component of a mobile electrical circuit.

LOFA Industries President Peter Herbrand explains that his company builds its wiring harnesses as a way to help sell integrated packages with LOFA's control panels.

"Our core business is the controls for diesel engines," he explains. "We build the electronics and the wire harnesses which entails the engine wire harness that connects the panel to the engine. If the engine already has a wire harness, we'll adapt to the harness that's already on the engine."

When LOFA first was started in 1989, Herbrand was building the wiring harnesses himself, personally, in order to sell its panels. "We started as a very small company. We now have machines here that cut and strip the wire automatically. Crimps are done by machine, as well. We don't do those by hand unless it's low volume. Using the machine, you're guaranteed an air-tight crimp to prevent moisture from getting in there."

Herbrand is seeing a trend toward waterproof connections. In the past, he says, everything used basic, standard connectors. But since you never know where equipment will be installed and used, connectors had to become more robust and refined.

Other trends in the industry are noted from Russ Wright, corporate account manager, Commercial Vehicle Group, Monona, IA. "The design cycle has decreased around 50% because of technology, as well as the need to bring products to market more quickly." 3D CAD software like Pro/E allows the harness to be designed right the first time, and to be brought to market faster. "Also," he continues, "the development of LED lighting technology has lessened the need for power in most designs and allowed for "power management" controls to be introduced," he says.

"What we find," Herbrand says, "is that a lot of companies don't have the proper equipment to crimp their own wire harnesses. They're doing it by hand, and if you have a bad crimp, moisture gets inside and they'll eventually fail. LOFA uses Deutsch connectors, a brand that Herbrand claims is probably one of the leaders for connectors.

LOFA buys wire by the barrel. The wire is pulled through a machine where it is cut to the programmed length and strips it accordingly. The stripped and cut wire is then brought to the crimping machine where the wire is held up to a wire stop, a button is pushed and it crimps the terminal down onto the wire. The harness itself still has to be connected and routed manually. Many people use wire harnessing boards where the design of the harness is mapped out and it's a basic pattern to follow.

Wires can be tested, as well, while on the boards. Some companies utilize CAD software to design harnesses. LOFA has an engine simulator where the panel is tested along with the wire harness to ensure a functioning package.

To work with a new customer (without access to the piece of equipment) LOFA will send a generic wire harness of approximately 10 ft. of wire. "With that 10-ft. harness, you'll have one side that's terminated to a connector that matches our panel. What they do then is wrap that harness around the engine, put cable ties on it and put the appropriate connectors on by hand. They'll send that harness to us and we'll re-create it," says Herbrand.

He says, "The industry is changing because everything is going to electronic engines. Things are becoming more sophisticated because we are having to deal with CAN bus."