In many Australian industries, vibration is the leading cause of electronic failure. This is true whether you are running mining gear in Perth or medical tools in Melbourne. Furthermore, a poorly designed wire loom won’t just break; it will fail intermittently. This causes expensive downtime and makes repairs difficult. Consequently, building for durability is essential from day one.
1. The Real Cost of Vibration Vibration causes a problem known as “fretting corrosion” at the contact points. It also leads to mechanical fatigue where the wire meets the terminal. If the wire is not supported correctly, the constant motion makes the copper brittle. Eventually, the wire will snap. However, you can prevent this with the right manufacturing techniques.
2. Why Machine Controlled Crimping is Better Many people still rely on hand-crimping, but this is often a weak link. To ensure the highest reliability, we use machine-controlled crimps. Specifically, this provides two major benefits:
- Consistency: Every single crimp is applied with the exact same pressure.
- Gas-Tight Seals: A proper machine crimp creates a “cold-weld.” As a result, oxygen and moisture cannot enter the joint to cause rust.
3. Using Smart Strain Relief A loom is only as strong as its anchor points. Therefore, we use alpha-grade wiring and long-lasting wire restraints. These parts ensure that the weight of the harness does not pull on the connectors. By using this “floated” design, the harness absorbs movement without stressing the electrical joints.
4. Rigorous End-to-End Testing Every custom harness at OurPCB Australia undergoes strict quality checks. We don’t just check for a simple connection. Instead, we make sure the loom meets your exact design specs. Because of this, we can guarantee our work to be free from defects for five years.
Conclusion Reliability always starts at the design phase. Whether you are in Brisbane, Sydney, or Adelaide, our local team in Seaford is here to help. We can review your designs before they go into high volume production. In short, we help you get it right the first time.
Need a quote for a high-vibration application? Contact Mark at OurPCB Australia today.
