IPC/WHMA-A-620 ASSOCIATION CONNECTING ELECTRONICS INDUSTRIES ® Requirements and ® Acceptance for Cable and Wire Harness Assemblies Developed by the IPC Task Group (7-31f) of the Product Assurance Subcommittee (7-30) and the WHMA Industry Technical Guidelines Committee (ITGC) March 20, 2002 Users of this standard are encouraged to participate in the development of … This standard is a combination of the former US Navy standard with the same name as well as the former US Air Force Standard T.O. Wire Harness Safety which plays a critical role with electronics. IPC/WHMA-A-620B: Superseded by IPC/WHMA-A-620C: IPC/WHMA-A-620B Requirements and Acceptance for Cable and Wire Harness Assemblies-+ Bundled wires fit into compact and low-profile devices more easily and make for neater, more easily identifiable cable runs in larger installations. Cable assemblies and wire harnesses are complex, multipart systems comprised of various discrete components and designed to transmit data, power, and signal. WIRE AWG Page 7-9 SYNOPSIS OF WIRE & CABLE Pages 7-10, 7-11 MIL-STD-681 COLOR CODING Page 7-12 MINIATURE SIGNAL & CONTROL CABLES - COLOR CODING Page 7-13 ... #38 to #32 AWG. Of course, we all should adhere to electrical safety each and every day. These cookies do not store any personal information. 3.1.1. CABLE HARNESS ASSEMBLY . Yes, May serves as the month to promote National Electrical Safety. 4. During the construction process, known as fixturing, harnesse… First, let’s look a little deeper at Electrical Safety. This website uses cookies to improve your experience while you navigate through the website. For example, the Electrical Safety Foundation International (EFSI) is the premier non-profit organization dedicated exclusively to promoting electrical safety for home, school and the workplace. IPC/WHMA-A-620, Requirements and Acceptance for Cable and Wire Harness Assemblies enjoyed immediate international acceptance since its first release in 2002 and quickly became the most important process, materials and inspection standard for the cable and wire harness industry. Furthermore using the proper equipment and tools to tackle each project is another significant benefit with creating a safe work environment. According to the NASA technical standard, NASA-STD 8739.4, the mockup, commonly referred to as a ‘form board’, is used to account for all the physical restraints that are encountered by the cable or harness when installing on a platform. IPC/EIA J-STD-001C—Requirements for Soldered Electrical and Electronic Assemblies. 3.1. The diversity and complexity of these multipart products underscores the need for strict standards compliance with regard to assembly, inspection, and testing; the new IPC/WHMA-A-620 standard will help ensure quality and performance. (Image courtesy of Mkamara9540 per CC BY-SA 4.0). on Standards Help Ensure Peak Performance for Wire Harness Assemblies. WHAT YOU NEED TO KNOW TO DESIGN A WIRE HARNESS Wire Harnesses Were Designed and Manually Assembled on the Fly Historically, wire harness design was addressed during unit assembly. Another important factor that plays a role with a company deciding to outsource their wire assemblies includes safety as well. Crimping of solid wire is prohibited. The IPC/WHMA-A-620 publication has standards for a wide range of elements within a cable harness, including but not limited to electrostatic discharge protection, conduit, installation and repairs, crimping, pull-test requirements, and other operations that are critical to the production and function of cable harnesses. Kapton is a Dupont™ trade name. Any cookies that may not be particularly necessary for the website to function and is used specifically to collect user personal data via analytics, ads, other embedded contents are termed as non-necessary cookies. Cable-laced wire harness assemblies in a private automatic branch exchange (PABX) system. Although automation is increasingly used in the harness assembly manufacturing process, it’s not entirely infallible and a majority of cable assemblies are still hand-assembled, which introduces the potential for human error. This Standard shall not be rewritten or reissued in any other form not approved by NASA. The standard is a “collection of visual Quality Acceptability Requirements for Cable, Wire and Harness Assemblies.”, Additionally, to learn more about the IPC/WHMA-A-620, click here:  http://www.ipc.org/ContentPage.aspx?pageid=IPC-WHMA-A-620. Technology The strength and bending properties of the newly developed "high-strength aluminum alloy wire" are higher than those of copper wire (twice higher than the standard aluminum wire). Do you have news you'd like to share with our readers? Over the past three decades, Falconer Electronics has teamed up with the top electrical vendors based on durability and reliability to provide safe products. This standard does not provide criteria for cross-section or X-ray evaluation. Welcome to National Electrical Safety Month. The SHARP program works with small businesses who have made a commitment to operate an exemplary injury and illness prevention program. Typical plastic retainers work by having a set of “branches” that can be insert Standard Wire & Cable Co. Rancho Dominguez 2050 E. Vista Bella Way, Rancho Dominguez, CA 90220 (310) 609-1811 (800) 326-0006 FAX: (310) 609-1862 You also have the option to opt-out of these cookies. They are also better protected against shorts and fire and, in harsh-environment applications, better protect systems from shock, vibration, and ingress of fluids or particulates. Each wire harness has a specific purpose to integrate into a larger electronic network, which, in the modern world, truly does make wire harnesses indispensable. A braid is the standard coaxial cable outer conductor. It may be applied in one or more layers. In advance of wire harness construction, it is common practice for mockups to be developed. Wire harness assemblies are quick and easy to securely connect, which reduces installation time. Lastly, to learn more about Wire Harness Manufacturing, check out these helpful links: In addition, check out these helpful links on Ground Straps: Tel: 716-665-4176 The acronym SHARP stands for Safety & Health Achievement Recognition Program. Developed over three years in collaboration with 86 connectivity suppliers and original equipment manufacturers (OEMs), the standard guides the production of crimped, mechanically secured, and soldered interconnections, as well as the various activities associated with manufacturing complete cable and wire harness assemblies. You need to check to ensure that the harness proves to comply with the latest industry standards in various tests. These cookies will be stored in your browser only with your consent. 3. Ground Strap | Multi Packs | FREE SHIPPING. Wire Insulation Types used at Falconer Electronics Inc. Amazon’s Choice: Five Star Ground Straps Manufactured in the U.S. at Falconer Electronics, Types of Wire Terminals When Building a Wire Harness Assembly, Through Hole Assembly vs Surface Mount Assembly, Protect employees from workplace safety and health hazards, Follow OSHA guidelines on safety best practices to protect workers, Boosting morale by creating a safe and dynamic work environment for employees. AS9100C, a widely adopted and standardized quality management system for the aerospace industry. cable manufacturing shop at Warner Robins Air Logistics Complex, Times Microwave – Clarity Test Cable Phase Testing, Winchester – Powersnap and Minisnap Small Format Power Connectors, 2020 Harsh-Environment Connectivity eBook, Beyond Standards: IPC Helps the Electronics Industry Navigate Challenges, •   Medical Devices and IoT | Inventory of Knowledge, •   Woodhead Watertite Extreme Wiring Devices:– 14W47, •   VITA 67.3 Contact Installation & Removal. We will contact you soon. Serving the electronics industry since 1985, our team has developed the experience and expertise to deliver products in the safest manner possible. The A-620 standard was written to be applicable to a wide array of cable and wire assemblies, such as this harness for an electronic fuel injection system. In response to the above challenges and requirements for high voltage cables for electric vehicle applications, it is necessary to establish new cable standards to meet the needs of suppliers, wire harness … Following IPC Wire Harness Assembly Standards offers tremendous benefits for Wire Harness Manufacturers. Let’s look at a few defects that hamper wire harness safety. 11. • In the 1970’s the main type of wire chosen in the aircraft industry was Kapton™ insulated wire. Out of these cookies, the cookies that are categorized as necessary are stored on your browser as they are essential for the working of basic functionalities of the website. 01-1A-14 and former US Army standard TM 1-1500-323-24-1. Yet, wire harness assemblies provide the necessary protection to contain loose wires. Now the wires of choice are typically: TKT (Teflon/Kapton/Teflon), Teflon™, Tefzel™, and Cross Link Tefzel™. Tips for Choosing the Best Automobile Wire Harness Manufacturer Recent Posts. How the Global Harmonization of Wire Harness Standards Will Impact Heavy Equipment Specification Decision Making. Necessary cookies are absolutely essential for the website to function properly. In the 1990s, the common soldering standard was MIL-STD-2000. Many companies find tremendous profit potential by. info@falconerelectronics.com. This specification describes a method and acceptance criteria for testing automotive wire harness retainer clips. 2. SAE AS50881 lists the current carrying capacity for most common wire gauges. There are many benefits with belonging to the SHARP program: Let’s dig specifically into wire harness safety. Factors include efficiency, price, experience, as well as possessing the proper tools and resources. EFSI founded National Electrical Safety Month. At Falconer Electronics, we are dedicated to ensuring the safety of our employees as well as all products that we produce. Key trends impacting cable assemblies include miniaturization, increasing speeds and data volumes, and fiber optics adoption. Numerous agencies and organizations exist that are dedicated to electrical and workplace safety. Kord King is a manufacturer of wire harness and cable assemblies for virtually any application including the Military, Medical and Health Care industries, the gaming industry, product dispensing industries, and many others.. Kord King can customize wire harness and cable assemblies to meet your specifications as well as provide engineering capabilities with complete documentation. Exceptions include power harnesses where the size of individual wires shall be a minimum of 22, and thermistor wiring where wire sizes smaller that 24 may be considered for use. Your drawing has been received. Sleeving shall be snug, secured at both ends and shall not slide freely. … This is a brief explanation of cable assembly vs. wire harness, and how each product is used out in the world. Email the editorial department at editor@connectorsupplier.com. In addition, Falconer Electronics exhausts every effort for accuracy and reliability. This is the only industry-consensus standard for Requirements and Acceptance for Cable and Wire Harness Assemblies and the most widely used inspection specification for the cable and wire harness assembly industry. For companies in electronics manufacturing, contributing to consumer safety is paramount. The wire harness has succeeded in reducing the weight and cost to a level lower than those of current products. Through specific requirements and standardized processes, these documents assure compatibility between networks. IPC/WHMA-A-620C Requirements and Acceptance for Cable and Wire Harness Assem… 4.9.1 Wire and cable - Wire and cable conductors shall be high conductive stranded copper or copper alloy. Photo courtesy Gasgoo Corp. Chapter 15 of the A-620 standard covers the process of taping wire harnesses. NASA-STD-8739.4 [9.3] ACCEPTABLE. 21046 - … Additionally, many cable assemblies are application-specific, custom products, so there’s little repetition, which can also increase the potential for errors. As a Wire Harness Manufacturer, we can certainly attest to the importance of Electrical Safety. Automotive wiring harnesses range in size and complexity from small, application-specific harnesses like this to complete chassis-length harnesses that weigh hundreds of pounds and interconnect the various electrified and networked systems. Also, handling the proper energy load is crucial. Otherwise a short can occur causing serious damage to the wire or even cause an electrical fire. Privacy Policy | ©2020 All Rights Reserved. This Standard cancels NASA Assurance Standard (NAS) 5300.4(3G-1), Workmanship Standard for Interconnecting Cables, Harnesses, and Wiring, and NASA Handbook (NHB) 5300.4(3H), Requirements for Crimping and Wire Wrap. By Bob Rensa, Heavy duty equipment original equipment manufacturers (OEMs) continue to face challenges like global competition, compressed development cycles, fuel economy and regulatory standards, but are also being tasked with the great responsibility of … This category only includes cookies that ensures basic functionalities and security features of the website. IPC/WHMA-A-620DS: Space and Military Applications Electronic Hardware Addendum to IPC/WHMA-A-620D-+ They are recognized in the Cable and Wire Harness Industry through their understanding of the value of the IPC/WHMA-A-620 certification – the worldwide benchmark for quality workmanship. Wire harnesses range in complexity from a few individual wires going point to point to hundreds of individual wires, multiconductor cables and welded wires all forming a complex wire harness used to transmit power and all types of data. For example, loose cables and wires can prove to be extremely dangerous. This wire harness is now crucial for vehicle efficiency and safety. As the use of these products increases across multiple markets, this new standard will provide increased end-user reassurance in terms of quality workmanship and performance. For example, the Electrical Safety Foundation International (EFSI) is the premier non-profit organization dedicated exclusively to promoting electrical safety for home, school and the workplace. Myriad manufacturing standards are applicable to aerospace wire harnesses. They may need to be concealed behind walls, fit … Multiple wires and termination points mean multiple points of potential failure, as each wire must be securely encapsulated, captured, crimped, and fastened. For example, this includes instituting wire harness safety during the assembly process. Requirements and Acceptance for Cable and Wire Harness Assemblies . Every electronics market utilizes these assemblies, and demand is increasing across numerous application areas. In light of these trends, the Wire Harness Manufacturer’s Association (WHMA) and IPC Association have issued the IPC/WHMA-A-620 standard — a new revision to the only industry standard that guides the manufacture of these critical connectivity products. In this market, steady demand for electrification and automation is driving an exponential increase in the wire content used in these designs, making durable, dependable wire harness assemblies even more critical. It is mandatory to procure user consent prior to running these cookies on your website. An example of a wiring harness layout. Wire Harness Safety Plays a Critical Role with Electronics Manufacturi... As a Wire Harness Manufacturer, we can certainly attest to the importance of Electrical Safety. But opting out of some of these cookies may have an effect on your browsing experience. Especially when it comes to Wire Harness Safety which plays a critical role with electronics. For example, loose cables and wires can prove to be extremely dangerous. The IPC/WHMA-A-620 standard prescribes practices and requirements for the manufacture of cable, wire and harness assemblies. Prewoven fabric (unvarnished) braid sleeving may be installed over the wire harness. (Image courtesy of Sir Boris per CC BY-SA 3.0). We also use third-party cookies that help us analyze and understand how you use this website. One particular area of growth is in automotive and non-auto transportation applications. These self-contained packages offer multiple advantages to system designers and installers. Retainer clips are plastic parts that hold a wire harness or electrical connector in a specific position. Stranded wire shall be used for crimping. The confusion is understandable since many professionals use the terms interchangeably and the products themselves have very similar basic functions. 4.9 Conductors. Scope/Purpose . Wire Harness Safety: IPC/WHMA-A-620 Standard . Design and assembly from the drawing board to finished wire harness requires step by step planning and a good amount of manual production. For 10 years, Bishop & Associates’ market directors and connector manufacturing experts have provided exclusive information on the markets, products, and technology in the connector and wire and cable industries. Falconer Electronics also strictly follows industry guidelines and regulations for wire harness safety. Robin Guy, an electronics mechanic for the U.S. Air Force’s 569th Electronics Maintenance Squadron, manually assembling an F-15 Sniper Pod wiring harness in the cable manufacturing shop at Warner Robins Air Logistics Complex, which, in partnership with Lockheed Martin, is the sole repair source for the Sniper Pod. Especially when it comes to. Greenstock In-connect is proud to be one of the few UK manufacturers to produce cable and wire harness products to the IPC/ WHMA-A-620 Standard (now, Revision C). IPC-A-610—Acceptability of Electronic Assemblies. The standard describes materials, methods, tests and acceptability criteria for producing crimped, mechanically secured and soldered interconnections, and the related assembly activities (corresponding lacing/restraining criteria) associated with cable and harness assemblies. The standard provides criteria on safety wires and preparation, the requirements for individual wire seals, soldering to terminals, the crimping of both stamped-and-formed and machined contacts, insulation displacement connectors (IDCs), ultrasonic welding, splicing, connectors, molding, marking, coax/biax cables, raceways, grommets, shielding, assembly, the overmolding of flexible flat ribbon, and wire-wrap terminations. 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