With an estimated revenue of $278.43 billion, the aerospace industry is a huge and profitable space that grows at a rapid pace. However, this growth demands specialized products and materials in order to work properly within the required security and quality standard.

In this article, we will cover one of the elements that plays an essential role within the aerospace industry: wire harnesses. To understand how wire harnesses and the aerospace market come together we will go over the history of this niche, while also exploring how technology has evolved and arrived at the need for wire harnesses.

A Brief History of the Aerospace Industry

The aerospace industry was first established in the 19th century, and it has been steadily advancing since then. It all started with the Wright Brothers’ first flight in 1903, which paved the way for the development of the aviation industry. Over time, aircraft became faster, safer, and more efficient, making air travel accessible to more people than ever before. Then, in the 1950s and 1960s, the aerospace industry turned its attention to space exploration, leading to some of the most significant technological advancements in history, such as the moon landing in 1969.

From airplanes and helicopters to rockets and spacecraft, this industry has touched every aspect of our lives. And, with its undeniable growth, is also responsible for creating well-paid jobs, and career paths for professionals with technical skills.

Challenges in the Aerospace Industry  

The aerospace industry is unique in that it operates in extreme conditions, such as high altitude, extreme temperature changes, and high-vibration environments. These conditions can be particularly challenging for electrical systems and components, which must perform reliably under these conditions. Functioning within this context makes most of its design processes long and complex, as it is important for engineers to reach a complete understanding of what works and what is less likely to succeed.

Additionally, aerospace systems must meet strict safety regulations and certifications before they can be approved for flight. Every advancement comes with a slew of new regulations to implement while also setting new quality expectations.

What are Wire Harnesses? 

Although first introduced to the market in 1929 by Sadami Yazaki, the invention of wire harnesses is usually attributed to the renowned inventor Charles Kettering. By grouping wires together and providing adequate protection, wire harnesses facilitate electrical communication, allowing different electric devices to function effectively over the long term.

While wire harnesses come in various shapes and forms, they all have three fundamental components: wires, connectors, and terminals. Wires are the backbone of the harness and require a physical structure to protect them from environmental hazards that could compromise the device they are powering. Connectors keep electrical signals flowing from one point to another, ensuring that the connection remains efficient. Terminals are found where the wire harness connects with another or ends.

Wire harnesses are critical for secure and efficient wire connections in any electric device, from cars to helicopters. Some of their main benefits are:

  • They provide a robust structure for wires to resist external conditions that might damage the infrastructure, such as abrasion and moisture. Each wire harness is uniquely designed to meet specific requirements, meaning that they come in different shapes and forms based on the type of wires used, the number of wires, and the installation environment’s specific conditions.  
  • Help internal connections stay organized and easy to access. Without harnesses, internal wiring can become a tangled mess, making installation difficult for technicians. Wire harnesses help wires stay organized and connected to a single source, making the process simpler and more straightforward. 
  • Allow for an easier troubleshooting and repair process if there is a defective part of the system.
  • Make it easier for technicians in the field to diagnose problems with specific components by testing components separately. 
  • Wire harnesses replace big structures that would be needed in order to maintain a secure, reliable connection. 
  • Are customizable and can be tailored to specific products, industries, electronic processes, and more. 

Wire Harnesses and the Aerospace Industry: Why Are They Important? 

The aircraft that operate in this industry require complex systems and components that must operate reliably and efficiently, and one of these essential components is the wire harness. They are crucial to wiring and electrical systems in aircraft, spacecraft, and other vehicles that operate in space. The wire harness is responsible for connecting all of the components in these systems together through a network of wires. Wire harnesses can be manufactured from copper wires, fiber optic cables, or other materials depending on their application. In addition, wire harnesses can help to reduce weight and increase the efficiency of aerospace devices. By designing wire harnesses to fit the exact specifications of a device or system, aerospace engineers can reduce the amount of excess wiring and components, reducing the overall weight of the device and improving its efficiency.

Compared to cables, wire harnesses are also much lighter, which is essential in aircraft manufacturing since weight is a critical factor that can impact flight performance and safety. Therefore, wire harnesses are preferred over cables to minimize weight while maintaining reliability and safety in aerospace applications, where carrying large numbers of passengers or cargo for extended periods is a key requirement.

Wire harnesses play a critical role in the operation of aerospace devices by ensuring that electrical power and signals are transmitted reliably and efficiently between different components. By using wire harnesses, aerospace engineers can simplify the installation and maintenance of complex electrical systems, reducing the risk of errors and increasing the overall reliability of the device.

Wire Harness Challenges 

While wire harnesses play a critical role in the operation of aerospace devices, they are not without their challenges. Even when wire harnesses represent an efficient solution to keep internal connections protected and organized, adapting them to the requirements of aerospace devices is not an easy path.

  1. Wiring Complexity: Electrical systems can involve a significant number of wires, connectors, and components. Wire harnesses simplify the complexity by bundling multiple wires into a single harness, reducing the number of individual connections and making the overall wiring arrangement more manageable.
  2. Wiring Errors: Traditional wiring methods with loose wires increase the likelihood of wiring errors, such as incorrect connections, reversed polarity, or crossed wires. Wire harnesses provide a pre-assembled and standardized solution, reducing the potential for human error during installation and minimizing the risk of miswiring.
  3. Space Limitations: In applications where space is limited, such as automotive or aerospace industries, efficient use of space is crucial. Wire harnesses bundle and route wires in a compact manner, optimizing space utilization and allowing for more efficient and organized wiring arrangements.
  4. Wire Protection: Wires in electrical systems are exposed to various environmental factors, including moisture, temperature extremes, vibrations, and mechanical stress. Wire harnesses incorporate protective features like insulation, shielding, and abrasion-resistant materials, safeguarding the wires against these elements and increasing their durability and lifespan.
  5. Maintenance and Repair Efficiency: Traditional loose wiring makes troubleshooting, maintenance, and repair tasks more challenging and time-consuming. Wire harnesses simplify these activities by providing organized and labeled wiring arrangements. Technicians can easily identify and access specific circuits or components within the harness, reducing downtime and speeding up maintenance and repair processes.
  6. Electrical Interference and Noise: In applications where electrical interference and noise can affect signal quality or performance, wire harnesses can include shielding features. Shielding helps to minimize electromagnetic interference (EMI) and radio frequency interference (RFI), ensuring signal integrity and improving overall system performance.
  7. Standardization and Compliance: Wire harnesses are manufactured to meet industry standards and regulations. They ensure consistent and reliable electrical connections, promoting standardization in wiring practices and facilitating compliance with safety, performance, and quality requirements.
  8. Scalability and Flexibility: Wire harnesses offer flexibility for future system expansions or modifications. They can be customized to accommodate changes in wire length, connector types, or configurations, making it easier to add or replace components without significant rewiring.

The complexity of aerospace systems and the harsh environmental conditions in which they operate can make the design and manufacture of wire harnesses particularly challenging. For example, the design of wire harnesses for spacecraft must take into account the unique challenges of spaceflight, such as exposure to radiation and extreme temperature changes. The wire harnesses must also be designed to withstand the vibration and shock of launch and the weightlessness of space.

Finding the Best Wire Harnesses for the Aerospace Market 

Wire harnesses play a crucial role in aerospace technology by protecting circuits and ensuring optimal performance. Designing wire harnesses for aerospace applications is a complex process that requires expertise and experience to meet the unique requirements of each device.

If you are looking for professional support in creating wire harnesses for your aerospace technology, look no further. Kauffman provides integrated engineering solutions from design to testing, ensuring that you receive a high-quality product tailored to your specific needs. Contact us today to receive the best-tailored wire harness solution for your aerospace technology.