Complex Wire Harness

Winchester Interconnect specializes in high mix/low volume cable assemblies, which are designed and produced within our global network of manufacturing facilities.

Because of our exclusive focus on providing the best solution to customers, we maintain an open-source connector policy for all our cable assemblies, utilizing all industry-standard manufacturers that meet the customer’s requirements.

The Winchester engineering team will provide support to develop, modify or finalize your product’s design and manufacturing drawings, including:

  • Review customer supplied documentation to ensure cable assemblies and wire harnesses meet IPC/WHMA-A-620 Class 3 requirements and are Designed-For-Manufacturability
  • Reverse engineer an existing product / design
  • Develop new cable assembly or wire harness design

3-D Modeling and Prototyping

Depending on the type of interconnect and design criteria used, Winchester Interconnect can apply simulation tools such as, electrical modeling, 3-D field and cascading analysis, along with mechanical modeling tools such as, 3-D mechanical analysis and thermal stress modeling. These tools are used to ensure that cable assembly products are best-in-class.

Cable assemblies often require the use of composite cables (a mix of different cable types within a single sheath) and Winchester Interconnect has a qualified division and a selection of specialist partner companies who will produce custom composite cables for each application’s unique design.

The cable assemblies and cable wire harnesses are built to IPC/WHMA-A-620 Class 3 standards (Requirements and Acceptance for Cable/Wire Harness Assemblies). This international standard is the industry quality standard for cable assemblies.

Wire harnesses come in many shapes and sizes, dictated by geometric and electrical requirements. They can be as simple as one or two wires terminated or bundled together, or can become a more complex product with many branches and a large variety of interconnects.

Engineering documentation and mock up, or prototyping, is critical during the design phase, as fit, form, and function need to be maintained to ensure accurate installation and proper performance.

Value Add / Electro-Mechanical Assemblies

Value Add Assemblies are commonly referred to as Electro-Mechanical, box build, or sub- assembly. Simply put, Value Add Assemblies are any type of assembly that requires a wire harness or cable installation to a PCB, device, or sheet metal enclosure, such as front panels, a small box build or PCB build.

Features & Benefits

  • Custom Configurations
  • Reduced Installation Time
  • Integration of Multiple Wire & Cable Types
  • Application of Multiple Interconnects
  • 100% Fit, Form and Function Validation
  • Testing to 2064 nodes
  • Unlimited Combinations
  • Reverse Engineering
  • Component Selection