Shaped Moulded Harnesses

Wires, fibre optics and tubes are encapsulated into a protective over-mould material selected to meet the mechanical and environmental needs of the system. This means that wiring systems can be configured to suit all applications.

A helicopter manufacturer has employed this system to route power and signal wires through the pitch horn and cyclic of a rotor head to the individual rotor blades. This application is one of the harshest environments that a harness can operate in. The harnesses are subjected to continual flexing, high vibration, extremes of temperature (-55°C to +120°C) and must be resistant to fuels, oils and de-icing chemicals. The harnesses complex shapes were constructed from 3D models allowing the design team to form harness shapes that fitted the product they are building, rather than providing space for a loose tolerance circular bundles with indiscriminate bends and fixings. Fixing points were integrated into the assembly, speeding up installation and reducing fatigue and chaffing on the harness. The harness shape is highly repeatable and close tolerance enabling repeatability and consistent performance.

Shaped moulded harnesses are available across a wide range of sizes and moulding materials enabling them to be configured for diverse applications. Tekdata “Teksol 340” is a high strength, tough and flexible material that meets all the above requirements. It is qualified for flight applications and is approved to FAR25 fire resistance.