Approaches to Wire Harness Design for Environmental Protection 

Wire harnesses are subject to numerous factors that impact their ability to function properly. From extreme temperature to chemical. Addressing these factors early in the design process is key to ensuring the harnesses’ reliability, safety, and durability. For this reason, ruggedized wiring is essential for harsh environments. What defines ruggedized wiring? Here’s an overview:

• Durable insulation: Ruggedized wiring typically uses insulation materials that are resistant to heat, cold, chemicals, and abrasion. Common materials include PTFE, silicone, and cross-linked polyethylene (XLPE). 

• Reinforced construction: The wires may be reinforced with additional layers or protective coverings, such as braided shields, to resist mechanical damage and wear.

• Sealed connectors: To protect against moisture and contaminants, ruggedized wiring often incorporates sealed or overmolded connectors, which prevent water, dust, and other particles from entering.

• EMI/RFI shielding: In environments with significant electromagnetic interference (EMI) or radio frequency interference (RFI), ruggedized wiring may include shielding to prevent interference with signals or electrical performance.

• Vibration resistance: Ruggedized wiring systems are often designed to withstand vibrations, which are common in industries like aerospace, automotive, and military applications.

Now let’s look at some examples of industries that typically operate in harsh environments that will require ruggedized wiring:

• Marine: Wire harnesses in marine environments face high humidity, saltwater exposure, and temperature fluctuations. Corrosion and water ingress are major concerns.

• Aerospace: These applications demand high reliability under extreme temperatures, vibration, radiation, and potential exposure to fluids (fuel, hydraulic, etc.).

• Industrial: Chemicals, oils, mechanical abrasion, and high temperatures impact wire harness performance.

Achieving Environmental Protection

Ensuring the longevity and reliability of your wire harness design in harsh environments requires protective measures:

Sealing and Overmolding

• Heat shrink tubing: Offers both mechanical protection and a moisture barrier by sealing the wire harness.

• Overmolding: Encapsulates connectors and junctions using materials like thermoplastic elastomers (TPE) or silicone, providing environmental protection and strain relief.

Connectors

• Sealed connectors: Designed to prevent water and dust ingress, with military-spec connectors like MIL-DTL-38999 commonly used in aerospace applications.

• Corrosion-Resistant Plating: Nickel or gold plating on connector pins helps prevent corrosion, especially in marine environments.

Routing and Clamping

• Protective conduits: Conduits made from materials like stainless steel or flexible non-metallic options shield the harness from physical damage and environmental factors.

• Proper clamping: Vibration-damping clamps minimize mechanical wear and reduce the risk of electrical failure due to vibration.

Ask us for a free demo 

As we’ve outlined, there is an intense need for ruggedized components when planning your wire-harness design when they’re expected to perform in rough environments. Arcadia schematic and wire harness design software is built with this in mind and helps streamline the process from beginning to end. When you’re ready to see how the platform elevates your design process, set up a time for a free, personalized demonstration.