Custom Industrial Automation Wire Harnesses

Please provide the equipment or application, connector types or mating interfaces, wiring diagram or pin assignment, operating voltage and current, signal or data requirements, cable lengths, conductor sizes, shielding, equipment movement, environmental conditions, branch configuration, quantity and required tests.

Drawings, equipment datasheets, photos or existing harness samples can also be provided for evaluation.

Connector selection depends on the mating interface, contact count, voltage and current, signal type, installation space, locking method, environmental conditions and expected connection frequency.

INTE-AUTO can evaluate push-pull, M8, M12, HR, threaded circular and other connector options according to the equipment requirements.

Pin assignments are confirmed from customer-approved wiring diagrams, equipment documentation, connector specifications or existing harness samples.

For multi-connector or multi-branch harnesses, each connector position, contact number and wire connection is documented on the harness drawing or wiring definition before prototype production.

Wire gauge should be determined according to operating current, voltage, cable length, allowable voltage drop, connector contact capacity, temperature conditions and available harness space.

Different circuits within the same harness may use different conductor sizes according to their electrical requirements.

Yes, when permitted by the equipment design.

A custom harness can contain power conductors, control wiring, sensor signals, twisted pairs or other required circuits. The internal construction, conductor separation, shielding and grounding should be evaluated according to the electrical requirements of each circuit.

Shielding depends on the signal type, cable length, surrounding electrical equipment and EMC requirements.

Sensor signals, encoder or feedback circuits, communication lines and other noise-sensitive connections may require twisted pairs, foil shielding, braided shielding, individual shields or an overall shield.

The shielding and grounding method should be defined according to the actual equipment interface rather than applying the same shielding structure to every harness.

For moving applications, the required motion type, bend radius, bending frequency, travel distance, cable routing and installation method should be defined.

These conditions affect conductor construction, cable flexibility, jacket selection, strain relief and harness routing.

A cable designed for stationary equipment should not automatically be assumed suitable for continuous movement.

Each branch should have clearly defined reference points, finished length and tolerance.

The drawing should also identify the main trunk, branch points, connector orientation, labels and cable exit directions. For complex equipment, connector IDs can be added to simplify installation and maintenance.

The connector keyway, alignment mark or another fixed reference point should be used to define the cable exit direction.

For equipment with limited installation space, INTE-AUTO can show the required orientation directly on the assembly drawing so it can be confirmed before prototype production.

Yes. Existing drawings or physical samples can be used as references for developing a replacement or customized harness.

INTE-AUTO can review the connectors, pin assignments, wiring, conductor sizes, cable construction, shielding, branch dimensions, labels, strain relief and other assembly details.

A new drawing and prototype should be approved before mass production.

Testing is defined according to the harness design and project requirements.

Standard electrical inspection can include continuity, pin-to-pin verification, short-circuit testing, insulation resistance and withstand voltage testing where applicable.

Additional mechanical, dimensional or functional tests can be defined according to the application and agreed acceptance criteria.

Mass production should begin after the prototype, drawing and technical requirements are approved.

Final confirmation normally includes connector part numbers, pin assignments, wiring, BOM, conductor sizes, cable specifications, shielding and grounding, finished lengths and tolerances, branch dimensions, connector orientation, labels, strain relief or overmolding, and required test criteria.

If the prototype requires modification, the documentation is updated and another sample can be produced for approval before mass production.