Wiring requirements vary from individual to individual. Your wiring application area and functionality will dictate the design, voltage, current capability, size, and colors, among other variables.
Therefore, dealing with a China wiring company that takes your needs seriously is essential.
Apart from meeting customer’s requirements, China wiring is under certain safety, design, and installation standards.
The rules and regulations are formulated by GB standards (GuoBiao Standards), China Compulsory Certification (CCC), and the International Electrotechnical Commission (IEC).
The IEC tries to harmonize the wiring standards globally. It has proven difficult as every country varies environmentally and structurally regarding electrical appliances, machines, and automobiles.
This article will provide detailed information on China’s wiring. From wiring and cable harnessing, color codes, designing, testing, and other wiring processes.
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CHAPTER 1: Cable Harness
A cable harness is a combination of two or more conductors that are insulated with a more intensive exterior product. Mostly, a cable will have a positive wire to carry current, a neutral one to complete the electrical path, and a grounding wire. After that, the whole combination is covered with heavy-duty materials such as shrink-wrapped thermoplastic, rubber or vinyl sheath.
Cable harnessing is a custom-designed assembly to ensure the product meets your specific logistic and structural requirements. Also, other factors are considered, for instance, temperature, humidity, size, shape, chemical substance exposure, fiction, colors and area of application.
We deal with highly qualified electrical engineers in designing cable harnesses, thus ensuring quality from the start. After that, we are solely responsible for testing that every harness will provide its optimum function. We confirm its durability under different environments, desired functionality and the place of application. Ultimately, we come up with quality-defined standards for manufacturing a cable harness.
Aside from acquiring standard processes, we also develop a methodology to develop some of our tools, plastic, dies, glass, metal, and synthetic materials. To bring all the materials and tools together, we have a highly designed and developed process with qualified technicians to ensure the manufacturing process goes smoothly and efficiently.
1.1 Cable Assembly Process
The cable design process entails the following:
- Cutting and shaping cables to the required lengths
- Installing the wires, cables, and components (subassemblies) on the assembly or pinboard
- Routing and attaching subassemblies with terminals and through other connector housing or sleeves
- Attach the subassemblies to the board with wraps, weaves, ties, or tapes
- Where possible, soldering of wire ends with a solder machine
Nevertheless, this is just a general process of what cable assembly entails, not a specific step-to-step process. Also, automation of the whole process has proven difficult as manual cable harness is more cost-effective considering the numerous activities involved. However, the initial parts of harnessing and kitting can somehow be automated.
Ultimately, we have a complete functioning and high-quality product for your use. The whole China wiring harness involves a balance of accuracy and speed, ensuring every item meets the standard protocols.
1.2 Cable Harness Testing
Before releasing the wire harness to you, we ensure the cable harness meets the geometric and electrical requirements through thorough testing and evaluation by our experienced team. Repeat purchases of similar products over the years have allowed us to develop standard products and save time in the harnessing process, testing, and installation.
What is an Automobile Wire Harness?
Automobile wire harnesses can simply be described as the assembly of electrical cables for the transmission of signals (wire harnesses) in automobiles. Wire harness plays an important role in some functionality of automobiles and space/aircrafts considering the amount and length of wires involved in their construction. Wire harness ensures the wires are more bound and thus safe from damage through abrasion, vibrations, and moisture.
Also, the constriction of the wires saves much space, and since they are bound into slave sleeves, the possibility of electrical fires occurring is minimized.
CHAPTER 2: China Cable Harness Heat Shrink Tubing
Cable harness, unlike wire harness, as you will see later, requires more great insulating materials.
It involves bundles of wires and cables, and the connections are made for sensitive machines, automobiles or aircraft. Therefore, caution and precision are mandatory.
2.1 Protecting Cable Harnesses
Heat-shrink tubing:
This is an efficient insulation technique, especially when the cable harness is used in an environment with diverse temperature levels.
Plus, it can be useful in handling chemical erosion, abrasion or even water damage.
Spiral-wrap tubing:
This technique allows the flexibility of the cables and wires in the harness. It involves a wrap tubing with openings that provide passage for the assemblies to join or separate from one group to another.
Split loom tubing:
The loom tubing is a method that ensures the connections remain intact. The tubing has small openings along its length.
Through these slits where the wires and cables are installed, and after installation, they close, keeping the assemblies surrounded.
Sleeving:
This method deals with sleeves, especially those made with braided-like material such as polyethylene; these allow flexibility at severely low temperatures. Also, some sleeves expand in situations where a lot of wrapped wires are involved.
Tape:
The use of tapes in designing cable harnesses is among the standard parts of the process. However, it can also be automated.
The tapes can have different backings such as cloth, foam, PVC, or felt.
In the above insulation techniques in China wiring, the heat-shrink tubing has proved to be more effective at providing cover against damage.
It is a recommendable method for a cable to either a manufacturer or you.
2.2 Features to Consider in Heat Shrink Tubing
The heat-shrink tube as a product has different brands. Some offer one unique feature, while some have combined benefits, and choosing one that suits your needs best is up to you. Here are separated characteristics a heat-shrink tube could offer:
Temperature tolerance:
This is suitable tubing if the cable harness is used in an environment of extreme temperatures, cold or heat. For example, in an automobile or a factory machine, much heat will likely be emitted.
Chemical resistance: You should know what type of chemicals and their concentration level; your harness will be exposed. They can either be acidic or basic; after that, you can choose a tubing that properly protects against that chemical damage.
Strength:
This is a feature to consider, especially when your cable harness is exposed in public. The tubing material should, therefore, be sturdy enough to make it difficult to impregnate the wires.
Abrasion resistance: Friction will majorly result from movements in the area of application of the cable harness. Consequently, erosion and heat will be the result.
Therefore, other than being abrasion-resistant, the tubing material ought to be able to withstand heat. It is significant considering the damage and loss that can occur if the wires get exposed to extreme heat.
Electrical insulation:
How much voltage will pass through your cable harness wires? The number of voltages is essential because it helps Chinese wiring manufacturing use wires that can handle the current.
Flexibility:
The flexibility depends on the size of your insulated wire harness and the area in which the cable harness is installed.
Flexibility in tubing ranges from very elastic to rigid, and it is up to you to choose which suits you.
Water resistance:
If you need a watercraft cable harness, water-resistant tubing is where you should go. However, in consideration of what type of water the harness will contact, is it fresh or salt water?
Shrink factor:
No, this is not similar to flexibility. It understands the degree of shrinking that can occur and finds the material with the ratio to withstand the change.
UV protection:
If your cable harness were exposed to sunlight for a long period, UV- resistant tubing would be very useful.
Flame resistance:
In a more severe environment with flames involved, apart from the temperature-tolerance feature, flame resistance tubing can come in handy in protecting the cable harness.
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Chapter 3: Chinese Wiring Color
Manufacturers, contractors, engineers, electricians, and traders all over the globe use different electrical wiring color codes for electrical distribution in residential homes and industrial buildings and wire and cable installation.
Some power cable and wire color codes are required, while others are optional. Using a standard wiring color code during installation provides several key benefits.
For example, using consistent colors makes it easier to identify the ground, line, and neutral wires to enable easier tracing of circuits, thus facilitating troubleshooting and maintenance tasks.
Furthermore, having a standardized color coding system helps protect electricians as it is easier to differentiate live wires from neutral ones.
Sticking to a set color code saves valuable time when dealing with electrical systems since technicians and electricians don’t have to spend as much effort figuring out what type of wire is connected to what, as the colors immediately provide the information.
Overall, standardized wire and cable color codes create a safer and more efficient environment for everyone.
Various colors are used for different cables and wires in different regions for single-phase, alternating current (AC), direct current (DC), and three-phase for design and installation according to local rules, regulations, and codes.
One of the most popular is the International Electrotechnical Commission (IEC), which most European countries, the UK and Argentina, follow.
Another popular code is the National Electric Code (NEC) that Canada and the US follow.
Now, let’s discuss the wiring color codes for China that detail the standard wiring color codes for fixed and flexible cables.
Flexible Cable
The wire color codes from this category are power cables, lamp cords, and extension cables:
- Neutral (N) – blue, black
- Line (L) – red, green, yellow
- Protective Earth (PE) – yellow-green striped
Caption: Extension Cord
Fixed Cable
The wire color codes from this category are three-phase color chats, including cables behind, on, or inside walls.
- Neutral (N) – blue, black
- Three Phase, Line 1 (L1) – yellow
- Three Phase, Line 2 (L2) – green
- Three Phase, Line 3 (L3) – red
- Protective Earth (PE) – yellow-green striped
Caption: Electrical Wiring Gong Inside a Wall
CHAPTER 4: China Wiring Harness
Unlike cable harnesses, china wiring harnesses deal with connecting single conductors. Wire insulation has little effect in protecting it unless in a situation where the wires are thick, as they are at higher risk of damage from a burned fuse. Also, jacketing is mainly employed on wires to be used under dust, extreme temperature, moisture, and friction, for example, in a remote or housing shell.
A wiring harness integrates wiring components into a single unit, thus simplifying manufacturing a huge, complex writing system. Also, it allows for an easy-fix installation and modification in case of damage to some components.
Therefore, China wiring involves assembling different wires that may or may not have the exterior covering. The wire harness is a cost-effective means of creating an orderly and carefully fitted wiring system. To achieve an effective harness design, there is a need to evaluate the different types of cables you use, styles, and materials.
For example:
For example:
- Insulating colors
- Color codes
- Shielding and heat-shrinking coats
- Lacing and wire-tires
- Labeling and barcodes
- Polypropylene, nylon, and paper fillers
Additionally, the area of wire harness application should be known and considered. It includes factors such as size, chemicals that will come in contact with the harness, temperature, humidity, and friction. These variables will facilitate the creation of the design model regarding the size and components the harness will use.
We aim to build our customers a long-lasting, durable, affordable,, quality product. Thus, we employ our best stechnicians, tools, and technologies to assemble cables, connectors, pins, and other materials.
4.1 Wire Harness Design
After building the harness design model, designing begins with the development of a blueprint for manufacturing and a pinboard for hosting the harness. The pin or assembly board is a representation of the harness. It indicates all the components and their location and serves as a working table for the wire harness.
The wires to be assembled come in a master reel, cut into the desired lengths, and printed for labeling and bar codes where required. With the required lengths, the wires are stripped off at the end to fit the terminals and connector housing where necessary.
The wires are placed on the assembly board and attached with suitable lacing, wire ties, tapes, strings, weaves or straps, or a combination of the components.
Over time, there have been attempts to advance manual wire harness designing to automation, but as the process involves many activities, most of the stages of the process remain manual. Nevertheless, some parts of the process have been automated for speed and accuracy.
4.2 Wire Harness Testing
Once wire harnessing is concerned, the process is not complete until testing for the real-world application is done. Testing is usually conducted with our expert staff, who employ the help of a test board.
A test board evaluates the electrical functionality of the wire harness. It is pre-programmed with electronic features, and once the complete wire harness is connected, it provides results of its performance or in comparison to certain values.
CHAPTER 5: What to Look for in China Wiring Manufacturers
Wire or cable harness may seem like a typical job until you come to think of it regarding what and how much you could lose if there is an application of a poorly manufactured cable harness. Damage or failure of a wire harness could impact the devices connected to it. Consequently, you must have sufficient information on choosing the right manufacturer for your harness.
Tips for Evaluating Wire Harness Manufacturers
The quality, durability, and life of your wiring harness will have much to do with the manufacturer. Below are tips you can consider to choose the suitable manufacturer and manufacturer research.
The company history
A manufacturer’s longevity in China wiring is an assurance of a well-versed provider in the wiring harness. More time spent in the industry means accumulating knowledge, skills, practices, better methodologies and acquiring quality materials.
Also, it would help if you did not worry about discovering that your manufacturer closed the business without getting the job done. Like every industry, businesses start and get closed; a more rooted China wiring manufacturer will advantageously have you at peace.
Skill level and experience
As discussed earlier, automating the whole wiring harness process has become impossible. Therefore, standardization is less achieved with manual working thus making it easy for you to identify a quality finished product. It will depend on the level of expertise of the designers and manufacturers.
Quality control is also an aspect you can consider about your manufacture. It is mainly implemented during testing. Therefore, the company should have invested in high-testing technology. Efficient and optimal testing guarantees that your requirements for a quality and reliable wiring harness will be met.
Does the company cost complement the quality?
It is human nature to relate expensive with quality. However, your wiring harness rmanufacturer should be able to meet your component and product quality needs so that you will be happy to pay for it. The low cost of the service and the product could seem like a great deal, but look out, it does not come to bite you in the back.
Proper communication and interaction
Apart from working to achieve a quality product, the manufacturer should be attentive to your specific needs and put them into action. Additionally, when you reach out, the manufacturer should respond immediately and address your concerns. Communication should not be frustrating.
FAQ
Is Blue Wire Positive or Negative in China?
In the past, China used to use its old wiring color code; however, today, they use the IEC power circuit wire codes.
| IEC OLD & NEW AC WIRING COLOR CODES | |||
| PHASE SUPPLY | CABLE & WIRE | OLD IEC CODES | NEW IEC CODES |
| 3 – PHASE | LINE 1 (L1) | BROWN, BLACK | BROWN |
| LINE 2 (L2) | BROWN, BLACK | BLACK | |
| LINE 3 (L3) | BROWN, BLACK | GREY | |
| EARTH / GROUND (PE) | YELLOW-GREEN STRIPED | YELLOW-GREEN STRIPED | |
| COMMON | NEUTRAL (N) | BLUE | BLUE |
| 1 – PHASE | LINE (L) | BROWN BLACK | BROWN |
| China Old AC (Single & Three-Phase) Wiring Color Codes | ||
| Phase Supply | Cable and Wire | Color Code |
| Three – Phase | Line 1 (L1) | Yellow |
| Line 2 (L2) | Green | |
| Line 3 (L3) | Red | |
| Earth / Ground (PE) | Yellow Green Striped | |
| Common | Neutral | Black or Blue |
| 1 – Phase | Line (L) | Yellow |
Is Red Negative in China?
For DC, China sticks to the IEC color codes. However, you shouldn’t trust the cable insulation colors as electricians use the old and new color codes for DC and AC. Therefore, using a tester to confirm the negative, positive, neutral, and phase wires is always best.
| IEC DC WIRING COLOR CODES | ||
| Two-Wire Undergrounded DC Power System | Negative (L-) | Grey |
| Positive (L+) | Brown | |
| Two-Wire Grounded DC Power System | L+ (of a -VE Grounded) Circuit | Brown |
| L- (of a +VE Grounded) Circuit | Grey | |
| ‘M,N’ +VE (of a +VE Grounded) Circuit | Blue | |
| Three-Wire Grounded DC Power System | Blue | |
| Three Wire Grounded DC Power System | Positive (L+) | Brown |
| Negative (L-) | Grey | |
| ‘M, N’ Mid Wire | Blue | |
| Earth / Ground (PE / PG) | Yellow Green Striped | |
Conclusion
Wiring, whether wire or cable harnessing, is a task that requires expertise and experience for a quality end product. We at Wringo are committed to providing outstanding wire harness solutions. Through our expert technicians who understand and are familiar with the required standards of China wiring, we deliver nothing short of the best.
With years of experience in wiring and manufacturing related materials, we have mastered the skill and perfected the art of understanding and making your ideas come to be. Contact us any time; we will be glad to serve you.
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Explore our custom services now. Email us at [email protected] for more details.
