This document summarizes Edgar Auto Harnesses Ltd, a privately held wire harness manufacturer established in 1999. It has over 250 employees and is ISO 9001, IATF16949, and UL certified. The company provides customized wire harness solutions and has experience in automotive, industrial, and medical industries. It focuses on quality, speed, and value-added engineering solutions for customers.

1. Professional
Wire harness manufacturer
Edgar Auto Harnesses Ltd
2018 Rev.1

2. Professional
Wire harness manufacturer
Edgar Auto Harnesses Ltd
2018 Rev.1

3. 东莞市艾得格车配件有限公司
 Privately held company, established in 1999
 Sales volume over 16 Million USD (in 2017 )
 OEM & ODM company, with employees more than 250
persons, 7260 square-meters in size, in 2018
 IATF16949 (2016) & ISO 9001 (2015), and UL certified
supplier with the No. E468011 for wiring & E479323 for cable
 Authorized as golden supplier of Alibaba.com in 2018
COMPANY STATUS

4. 1
2
3
4
Quality: IATF16949 & ISO 9001, and UL certified supplier with employees well trained by IPC
620 and complete control procedures.
Speed: OEM & ODM company with independent prototype samples shop and quick
engineering solutions.
Value added: Low failure/maintenance rate, quick solutions to help customers
increase marketing opportunities
Expertise: Specialized in wire harness since 1999 with rich experience, developed thousands
of products and molds which cover many industries and are exported to all over the word.
ADVANTAGE

5. CUSTOMIZED DESIGN SOLUTION
 Customized design
 Assembly solutions
 Multi-process
 Special requirement
 Tooling design
 Prototype sample

6. BASIC TOOL FOR OVER MOLDING
 Custom and standard over molding tool are the basic engineering and design in Edgar, with 20 years experience
on these since our company established in 1999.

7. OVERMOLDED STRAIN RELIEF DESIGN
 Over-molded Strain Relief is based on the Cable diameter, rib style, slot thickness, slot shape, inner flange. The
purpose is to help customer's cable assembly, seal or even waterproof in somewhere, prevent the cable
damage from over bending or installing.

8. MOLD DESIGN
 Mold design and fixture design are the core service in Edgar, The molds for plastic parts, silicone rubber parts,
stamping parts, and die-casting parts etc. The fixtures for test, assembly.
 To assist custom cable /wire harness assembly design
 Economical and qualified solutions
Cooling analysis
Ejector solution
Back moldInjection mold design
Front mold

9. Injection Mold
Mold-flow Analysis
Mold core design
Back mold Front mold
MOLD DESIGN

10. AUTOMOTIVE CABLE / WIRE HARNESS DESIGN
 Our design service have covered various Automotive service parts already. Our engineers focus on customer
concerns, the reliability & safety are always the first priority in our design. The design procedure strictly flow
IATF 16949 quality management system, and some f the process are complicated
Engine wire harness
Hybrid battery wire
assembly
ECU wire harness
Audio wire harness
Mirror wire harness
ADAS wire harness Auto seat wire harness
Buzz for sensor harness
Lamp harness
Fuel pump harness
OBD II diagnosis cable
GPS cable assembly

11. J1939 DIAGNOSTIC CONNECTOR
 The J1939 belong to HD series, which is following CAN (controller area network) protocol standard and the pin-
out is defined by SAE (Society of Automotive Engineers). The HD series including J1708, J1939 etc. ,is an
environmentally silicone rubber sealed, thermoplastic cylindrical connector, which is designed to be a faster,
easier, trouble free assembly diagnostic connector in heavy-duty industry like truck, bus, cross-country vehicle,
crane and forklift etc. When mated, the contacts are protected from water, dust, lubricating oils, fuel, road salt,
grease, mud and other contaminants encountered.

12. SOLUTIONS ASSESSMENT
 Wiring harness for animal blood analysis system
 Durable and low failure and maintain
 Easy assembly & maintain solution

13. Plating material Temperature Conductivity Cost Advantages Disadvantages
Bare N/A Excellent General Low cost Oxidizes
Tin 150℃ General High Aids soldering Poor at high frequencies
Nickel 250℃ Good Expensive High frequencies/ temperature N/A
Silver 200℃ Excellent Expensive High frequencies/ temperature N/A
DESIGN CONSULTANCY
Conductor selection
 The higher number of strands the higher cost ,most conductors have strand count 7 strands (the least expensive) ,to
achieve flexibility requirement .
 Plating or coating applied to the strand increase the cost of conductors, but for some bare copper is more expensive than
plating / coating conductor due to the lack of popularity.
 Both voltage and current needs will dictate the size of the conductor needed.
Base material Conductivity Flex life Cost Advantages Disadvantages
Copper Excellent Good General Low cost Oxidizes
Copper alloy Good Excellent Expensive Flex life High cost
Copper weld Excellent Good High Strength Flexibility

14. Tolerance design
 The tighter the tolerance, the more difficult assembly will be, and the high cost is required. For very specific electrical
characteristics, routing assembly which is impact overall cables. In some application adherence tolerance is stated in
IPC/WHMA 620
 The tolerance design should consider the different process such as the molding, heat shrinkage tubing, and the length of
cable.
Shielding design
 Select shielding solution both consider economic and the correct combination to meet the application
Shield type Flexibility Cost Advantages Disadvantages
Tape General Cheap Low cost Poor flexibility
Braid High High Excellent at low frequencies High cost
Spiral Excellent General Pig-tail termination Poor at frequencies
Tape & Braid Bad Expensive Good performance High cost
DESIGN CONSULTANCY

15. Insulation jacket selection
 PVC : varying pliability & electrical properties, different temperature rating and price range varying accordingly.
 Fluoropolymer: excellent thermal, chemical, mechanical, and electrical characteristics , high price (roughly 8~10 times PVC)
some Fuoropolymer like PTFE will require the conductor with silver or nickel plating also driving up costs.
 Compounds TPE/TPR: good mechanical
Material Temperature rating Shore harness Cost
PE 75 ℃ 60A General
PP 80 ℃ 58A General
PVC 80 ~ 105℃ 16~46A General
TPE/TPR 105 ~ 125℃ 14~30A High
PU 80 ℃ 29~38A Expensive
FEP(Teflon) 200 ℃ 56A Expensive
PVC Alloy 60~70 ℃ 58A High
Kynar (PVDF) 125 ℃ 33-55A Expensive
DESIGN CONSULTANCY

16. The substitute selection
 In most all instances, the substitutes connector will perform as well as the original connector to cut down both lead time
and cost.
 For some connectors do not address electrical performance or dimension, mating connector is need to try-on test.
DESIGN CONSULTANCY

17. Contacts selection
 For harsh environments a sealed connector should be used to avoid assembly failures in the future causing unexpected
additional costs.
 Normally, a brass connector body is a good economical choice. Choose the correct contacts material Brass, Beryllium
copper, or phosphorous bronze for special circumstance. The choosing is decided by how often the connector will be
connected and disconnected.
Assembly solution
 To achieve flexibility assembly, high strand count conductors and compounds developed for continuous motion drive up
the cost. Hence, for installed in a stationary application, the economic solution is ignore high strand count conductor .
 Potting solution or sealing design are consider in somewhere for waterproof IP67/68 rating.
 For some complicated structure with undercut, ultrasonic welding assembly design is a choice to simplify the structure
but expend cycle time of the production .
DESIGN CONSULTANCY

18. LETTER OF PATENT
 Edgar’s R&D team not only with scientific management philosophy, but also have strong motivation
of craftsmanship sprit on studying and reflect on new engineering cases, till now they had finished
a dozen of utility patents.

19. CONTACT US
WWW.China-CableAssembly.com