Two leading suppliers of wire harness assembly equipment are celebrating their centennials at the National Electrical Wire Processing Technology Expo in Milwaukee this week.

In the near future, energy harvesting and inductive power transfer technology may replace electrical wires, power cords and batteries in a wide variety of applications.

Special equipment is needed to cut, strip and crimp coaxial cable.

Several unique technologies are available to error-proof connector assembly. Using lamps, lasers and real-time video, these products guide assemblers step-by-step through the assembly process, guaranteeing correct insertion.

Evolving technology, such as carbon nanotubes, fiber optics and printed electrical systems, may provide the backbone of future electrical distribution systems in cars, trucks, locomotives, aircraft and other vehicles.

Aluminum wire and cable can be more difficult to feed, cut, crimp, strip and splice than its copper counterparts. However, numerous processing methods are currently under investigation.

A guided harness assembly and test system makes sure that assemblers insert wires correctly by giving them instant feedback. If wiring errors can be detected when and where they occur, preferably by the assemblers, then quality goes up while overall cost is driven down.

Recent price fluctuations have forced some manufacturers to consider alternatives to copper wire, such as copper-clad aluminum, solid-core aluminum and composite wire.

Presses for terminating wires have benefited dramatically from advancements in electronic control technology.

Whether joining two wires together or attaching multiple wires directly to a terminal or assembly, engineers must choose between resistance welding, soldering and ultrasonic welding.