Manufacturing of a Transmission Wire Harness Protection Sleeve for the Automotive Industry

Wire Harness Protection Sleeve An automotive industry client asked S&A Industries to produce a tubular heat protection sleeve to be used on a wire harness for a high volume automotive transmission application. S&A engineers assisted in the custom-design, then developed and built the automated tooling required to cut-notch, crimp, pierce and assemble an eyelet feature for securing the sleeve to the wire harness. The S&A team also validated the thermal effectiveness of the sleeve in accordance to SAE J2302.The composite assembly featured a combination of non-woven insulating materials and highly reflective aluminum foils. The wire harness maintained a temperature of under 125°C when in operation just 150 mm from the 550°C heat source. Online automated inspection ensured the finished product complied with the customer-supplied specifications. For details, please see below .

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Manufacturing of a Transmission Wire Harness Protection Sleeve Project Highlights

Product Description This tubular heat protection sleeve is used on a wire harness for an automotive transmission.
Capabilities Applied/Processes Testing & Development
  • Tested to SAE J2302 Thermal Effectiveness of Sleeve Insulation to Determine a Material That would Meet the Proper Requirements
Automated Manufacturing
  • Developed & Built Custom Automated Tooling to
    • Cut Notch
    • Crimp End
    • Pierce Hole
    • Press Eyelet to Secure its Position on the Wire Harness
Equipment Used to Manufacture Part Custom Designed by S&A Engineers
Overall Part Dimensions 26mm OD x 100mm long
Material Used Composite assembly, aluminum foils and non-woven cloth
Material Finish Bright Aluminum
Technical Specifications Wire Harness Located 150mm Away from 550°C Heat Source
Wire Harness to Maintain a Temperature of Under 125°C During Operation
In process testing/inspection performed On line automated inspection using cameras
Turn Around Time 12 Weeks from Development to Build
Industry for Use Automotive
Delivery Location Globally
Standards Met SAE J2302
Customer Supplied Specifications
Product Name Transmission Wire Harness Heat Protection Sleeve

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