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Basics2 min read

Wiring harness, cable set, assembled cable: what is the difference?

In purchasing the terms are often used interchangeably. For design, production and the quote, however, the difference matters a great deal. An overview with examples from our production.

Wiring harness for an on board power system, built to drawing
From our production: Wiring harness for an on board power system, built to drawing.

Assembled cable

An assembled cable is a single cable that has been cut to length, stripped and fitted at one or both ends with contacts, wire end ferrules, cable lugs or a connector, for example a battery cable with cable lugs or a sensor cable with a circular connector.

Cable set or wiring set

A cable set combines several assembled cables that belong together in one application. They can be supplied loose, bundled or partly connected to one another. Examples are a connection set for a power supply unit and an extension set for electrical loads. In vehicle manufacturing the term wiring set is also common.

Wiring harness

A wiring harness is a component with a fixed geometry: several cables run bundled in a main trunk and branch off at defined points to connectors, sensors or electrical loads. It is assembled to drawing on an assembly board, protected with corrugated tube, braided sleeve, heat shrink tubing or tape, and installed as a single unit. In a vehicle the wiring harnesses together form the on board power system.

  • Main trunk and branches with fixed dimensions
  • Connectors, contacts and seals
  • Electrical nodes, for example ultrasonic splices
  • Protective sleeving, taping and fixing points
  • Marking of cables and branches

What this means for your enquiry

For an assembled cable the cable type, the length and the terminations are often enough. A wiring harness needs a drawing with branch dimensions, pin assignment and protection, or alternatively a sample from which the documents are produced. If you have neither, the wiring harness sketch in our enquiry form helps, or our design with EPLAN.

FAQ

Answered briefly.

Is a wiring set the same as a wiring harness?

Not quite. "Wiring set" is often used as an umbrella term for cables that belong together, and in vehicle manufacturing sometimes as a synonym for wiring harness. What matters is whether the cables are supplied as a bundled component with fixed branches. If they are, it is a wiring harness.

What is an on board power system?

The on board power system comprises all the electrical cables, wiring harnesses, connectors and fuses in a vehicle. It usually consists of several wiring harnesses that are joined at separation points.

Does Powertune produce all three variants?

Yes. We produce assembled cables, cable sets and wiring harnesses, from the single piece to series production. More under Cable assembly and Wiring harness manufacturing.