Cable assemblies and wire harnesses are core components and standard terms in the original equipment manufacturing (OEM) industry and beyond. Still, there is a lot of confusion surrounding these terms as they are often used interchangeably, even by experts.
While cable assemblies and wire harnesses serve similar functions – that is to bundle multiple wires and cables together, they have distinct differences that will help you decide which one you need.
A cable assembly is made up of multiple wires or cables that are wrapped together inside a single external sleeve. On the outside, a cable assembly looks like one thick wire. While a wire harness is made up of several individually coated wires or cables and provides a cover to keep them together.
- The difference between a cable and a wire
- What is a cable assembly?
- What are cable assemblies used for?
- What is a wire harness?
- What are wire harnesses used for?
- Cable assembly vs. wire harness
- A cable assembly has two ends while a wire harness has mutiple ends
- Cable assemblies are better for harsher environments while wire harnesses are more flexible
- Wire harnesses offer a low-cost solution while cable assemblies my be more expensive
The difference between a cable and a wire
Before we dive into defining what a cable assembly and wire harness are, we should first clarify the difference between a wire and a cable. These terms are also often used interchangeably, but they mean different things.
Wires are usually made either of copper or aluminum. Whereas cables are made of two or more wires that are twisted or bonded together inside a protective outer cover. Simply put, a wire is a component of a cable.
What is a cable assembly?
A cable assembly is a group of cables or wires grouped together in a single sleeve. The bundled cables or wires have distinct functions, however, they all feed through one or two end connectors or plugs.
What are cable assemblies used for?
Given that cable assemblies bundle several wires together, they are perfect for safely and efficiently organizing, installing, and routing different electrical wires.
Moreover, the outer sleeve in cable assemblies is made out of long-lasting materials like vinyl or thermoplastic, which serve to protect the inside cables or wires from environmental factors such as moisture, heat, or friction. This makes cable assemblies more durable and great for outdoor use where they can encounter and sustain harsher environmental conditions.
This is also where custom cable assemblies come in. Before purchasing and installing cable assemblies, you should take into account the environmental factors they are likely to come into contact with. Among other things, the environment will determine the material of the external sleeve.
Cable assemblies are commonly used in the original equipment manufacturing industry, especially in the mass production of automotive parts, control systems, medical and agricultural equipment, and more.
What is a wire harness?
A wire harness, on the other hand, is an exterior wrapper that bundles together cables and wires that are already covered in an outer layer. Simply put, if you were to open a wire harness you would be able to see several individually insulated wires inside.
What are wire harnesses used for?
A wire harness is primarily used to group different wires or cables with the purpose of transmitting a signal or electrical power. By grouping the wires together, you won’t have multiple wires all over the place. Instead, by using a wire harness you can organize your electrical system for easier connectivity.
Differently from the outer layer of a cable assembly, the wire harness sleeve is not designed to protect the cables or wires it holds inside, but rather it is designed to hold them together. The wire harness sheath material is predominantly made out of thermoplastic, or it can even be something as simple as a nylon thread that keeps the cables together. This means that wire harnesses are less durable than cable assemblies and better suited for indoor use.
Therefore, the main purpose of a wire harness is to organize multiple wires and cables that serve different functions for easy routing while adding a mild layer of protection to them. Based on your specific needs, you can use custom wire harnesses to fulfill your goal. For instance, custom wire harnesses are widely used in engines of all kinds, such as automobile engines and household appliances.
Cable assembly vs. wire harness
Now that you know what a cable assembly and a wire harness are and what they are used for, we will sum up and dive a bit deeper into some of the main differences between the two.
A cable assembly has two ends while a wire harness has multiple ends
As mentioned above, a cable assembly has two ends, which can be plugs, connectors, and terminals. You may use a cable assembly when you need to create a path between one point to another. A wire harness contains multiple ends, meaning that you may use a wire harness to connect several end-to-end wires or cables in an organized manner.
Cable assemblies are better for harsher environments while wire harnesses are more flexible
This point is linked to the layers of insulation that a cable assembly and wire harness have. A cable assembly is coated in long-lasting materials, made to withstand harsh environmental conditions. In contrast, the outer layer of a wire harness is designed to group the wires and cables together, providing a lower level of insulation. While the wires and cables inside the wire harness are individually insulated, a wire harness is not as durable as a cable assembly.
On the other hand, the durable cable assembly sleeve makes them more rigid, While, a wire harness is more flexible and weighs less. So, wire harnesses may be a better choice if you need to connect things in a small and tight space and cable assemblies may be best if durability is more important in your case.
Wire harnesses offer a low-cost solution while cable assemblies may be more expensive
While the cost of a wire harness and a cable assembly will depend on a few factors, this statement is generally true.
Wire harnesses tend to be cheaper as they do not require the design and engineering of a protective external sleeve that needs to meet specific environmental and performance requirements.
Moreover, since a wire harness is essentially made of individual wires or cables, is easier and cheaper to add, remove, or replace wires when needed. While it is not possible to alter an individual wire inside a cable. When a cable assembly is damaged, you may need to replace the entire unit, which is not cost-effective.
In conclusion
Whether you need a cable assembly or a wire harness will depend on your specific job requirements. They are just different.
