Wire Harness Manufacturing Software​

Provide cost and time quotations:​

• Harness Builder for E3.series creates time and cost estimates for a harness driven by components such as connectors, terminals, wires, and cables. Quickly determine long lead times for parts using Harness Builder for E3.series Cost Estimator report.​

Capture parts and accessories:​

• Automatically generate a complete BOM driven by the project data. Various types of details, both explicit and implicit, are captured to maintain an up-to-date count of parts inside the project. The BOM automatically tracks components, wires, cables, looming parts, labels, splices, and other miscellaneous parts.​

Display on the Formboard drawing:​

• The BOM on a drawing sheet is formatted and configured per user requirements. The application automatically details the item’s numbers in balloons across the drawing and is in sync with the on-sheet BOM​

Configurable user-defined report:​

• A user-defined excel template enables precise control over the format and content of the report for downstream consumption. The wires, cables, labels, and loom are quantified based on length to provide accurate results. The link between the BOM and wire reports helps to maintain precise wire length and termination details.​

Detailed parts data:​

• Additional connector accessories are associated and easy to add to the BOM without searching for part numbers through OEM or supplier documentation. Selected elements hyperlink to PDF documents for information about sizing and terminal insertion.​

Dash Number configuration:​

• The dash number function creates multiple reports driven by the configuration options for the wire harness, along with a summary of all options.

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Wiring reports:​

• Automatically generate a complete configuration Wire Run List (WRL) driven by the project data. Various types of details, both explicit and implicit, are captured to maintain an up-to-date count of parts inside the project. ​

Display and share on Formboard:​

• The WRL on a drawing sheet is formatted and configured per user requirements. User-defined templates enable precise control over the format and content of the report for downstream consumption. The wire run lists track and update the wires, cables, seals, caps, and wire terminations. The link between the BOM and wire reports helps to maintain precise wire length and termination details. The combination of on-sheet and Excel reports bring versatility and robustness to the reporting process.​

Accurate lengths to drive manufacturing:​

• The application captures insertion lengths at the connector and termination level and other additional length factors to improve the accuracy of wire length calculations across the wire harness. The wiring data accuracy enables wire processing and testing machines to improve quality, reduce effort, and implement design standards.​

Automated wire harness testing:​

• Quickly drive automated harness testing machines directly from the design details. The export options for Cirris, DIT-MCO, Dynalabs, CamiResearch, Nexeya, CKT Technologies, and more provide an easy path to improved quality and time savings.​

Key features:​

• Create on-sheet wire run lists with termination details​
• User-defined options for sequence and terminations of wires​
• Capture wiring details like insertion length at connector and pin level to calculate wire lengths accurately​
• Excel output to drive multiple downstream processes​
• Drive wire processing and testing machines to improve quality and reduce the effort​

Splice documentation for sonic welders:​

• Splicing is an integral part of the wiring harness and manufacture creation. Harness Builder for E3.series will provide direct output, including barcodes for the ultrasonic welders. Thoroughly detail the left and right side welds and select the correct size heat shrink for the fabricated weld.​

Wire color details on connector views:​

• Documenting a harness assembly with the color of the wire connected to a pin is beneficial in increasing wiring efficiency. The wire harness’s loading and table views can display the wire colors on the terminals. Display additional details using configurable wire attributes to boost downstream processes.​

IPC/WHMA-A-620 wire tolerancing standards:​

• The addition of wire harness tolerancing blocks on the formboard to follow the IPC/WHMA-A-620 standard is available. The standard adjusts the wire length to increase on a sliding scale based on the routed length.​
• The tolerance setting options can be in imperial units, metric units, or a percentage. These settings are read from the drawing and configurable for individual harnesses.​

Formboard Copilot:​

• Formboard Copilot is a drafting tool to simplify creating a wiring harness on a size-constrained formboard.​
• The exact length of branches and trunks is always a challenge to manage perfectly the first time around wrapping a harness around a size-constrained formboard when the length is known in advance.​

Cable protection and coverings:​

• The application automatically calculates bundle diameter for parts selection. The coverage and slack calculation is configurable for multiple applications. Automatically apply across the entire wire harness or selected segments. Reports capture part numbers and details for use in assembly and manufacturing processes.​

Label placement:​

• The automatic label placement saves time and standardizes harness designs across projects effectively. The labels are for standard devices and connectors. The label placement option is highly configurable to handle the labels as independent parts or additional parts of the devices and connectors. Furthermore, automatically assign heat shrinks to device and connector terminations. The versatile solution provides complete auto-place options and an individual placement option.​

Tape placement:​

• Tape or other accessories are placed automatically on the entire wiring harness or selected branches. The calculation for the bundle diameter is automatic, and an appropriate tape is selected. The tape placement is configurable with offset, centering, and other selection standards to match various process requirements.​

Harness Builder for E3.series is loaded with a list of direct import and export functions. The intelligent harness data digitally drives a variety of automated manufacturing and assembly platforms. Connecting with 3rd party platforms creates a harness manufacturing ecosystem to improve quality and efficiency.​

Automatic wire processing machines:​

• Drive highly automated wire cutting and processing machines from vendors such as Schleuniger, Komax, and Argus using direct outputs from Harness Builder for E3.series.​

Automatic labeling:​

• Automatically print labels using popular machines from Brady, Brother, and Hewlett-Packard. The output and user formats are easy to create and deploy. Several laser marking, labeling, and other printing options are readily available to drive manufacturing automation.​

Augmented reality assembly solutions:​

• Manufacturing assembly aids like ‘HarnessWorks’ are driven directly from the harness assembly to enable smart manufacturing processes.​

E3.series offers a variety of solutions to improve the collaboration between MCAD and ECAD teams without redefining their respective roles. ​

• Intelligently verify and heal the most common 3D harness route segmentation issues without relying on the mechanical team.​
• The harness flattening functions simplify transitioning from a 3D harness export to a 2D formboard drawing. The connectivity between logical and physical architecture in E3.series improves data reliability with automatic updates across the entire project.​

Learn more

Simplify the time-consuming process of creating work instructions using the engineering data in harness builder for E3.series. Create, release, and manage work instruction packages to define the building process for the cable assembly. Pre-built customizable work instruction templates ensure consistency across projects. Auto-actions trigger repeatable custom automation routines to assemble relevant assembly instructions. The combination of comprehensive reports and configurable reports improves quality and increases productivity.​