Motorsport Harness Solutions
Electric harnesses and looms
Design reliable architectures, industrialize their manufacturing and guarantee their performance
XAP harnesses ensure the reliable electrical integration of competition and testing equipment. A real nervous system of any on-board equipment, the electrical harness ensures the distribution of energy and the transmission of information between computers, sensors, actuators and human-machine interfaces, while guaranteeing the integrity of communications in often harsh environments.
A poorly designed or improperly manufactured harness can compromise the performance of a vehicle, machine or system, regardless of the quality of the components it connects.
With its expertise in embedded electronics, XAP masters the entire value chain: Design of electrical architecture, industrialization, manufacturing, control, maintenance and document reconstruction of complex beams.
01 — Design
Design the harness with the whole system
The design of a harness is not simply about drawing links between different connectors. At XAP, it is part of a global co-design approach with electronic cards and embedded systems with which the harness will be associated.
The electronic CAD and harness design tools are interconnected to ensure perfect consistency between electrical diagrams, electronic cards, nomenclatures, mechanical layouts and plans necessary for manufacturing.
Each conductor, connector, protection, splice and marker is integrated into a structured digital definition. This continuity of information ensures the traceability of the product throughout its lifetime.
It also facilitates technical developments, limits the risks of error and accelerates the transition from design to production.
Electrical architecture • Diagrams • Connection • Installation • BOMs
02 — Industrialization
Transform an electrical definition into a controlled manufacturing process
The manufacture of a loom is based first on a complete and rigorous documentation.
Each project is associated with all the information necessary for its production: nomenclatures, manufacturing ranges, operating methods, control sheets and traceability documents.
This organization guarantees reproducibility between the different production series and simplifies maintenance, future modifications as well as the document management of the most complex projects.
To ensure consistent quality, XAP also automates preparation operations that require the greatest repeatability.
The conductors are prepared using automatic machines ensuring, in particular, their cutting, stripping and marking. This preparation guarantees constant dimensional accuracy as well as lasting identification of each wire.
Automation reduces manufacturing variations, improves production rate and ensures excellent repeatability, including on complex architectures that can have several hundred conductors.
Documentation • Automated preparation • Identification • Repeatability
03 — Manufacturing
Human know-how at the heart of the quality of the loom
The quality of a harness depends as much on its design and industrialization as on the know-how of the operators who make it.
XAP relies on personnel specifically trained in wiring, assembly and crimping techniques adapted to the requirements of the automotive, industrial, aeronautical or defense environments.
This mastery is essential to guarantee the reliability of high-density architectures, rapid communication networks or even power circuits subject to significant mechanical and environmental constraints.
The crimping operations are carried out using controlled semi-automatic stations to precisely control the forces applied on the contacts.
Mastering the process makes it possible to obtain a constant connection quality, reduce manufacturing dispersions and guarantee electrical and mechanical performance in accordance with the requirements of critical applications.
This repeatability is particularly important to ensure the long-term reliability of beams exposed to vibrations, thermal shocks and severe mechanical stress.
Wiring • Crimping • Assembly • Protection • Operator know-how
04 — Control
Each harness is checked before delivery
Before their delivery, all the looms manufactured by XAP are subject to systematic checks.
Dedicated test benches automatically check the electrical continuity of the various connections, the absence of inversion and short-circuit, the conformity of the wiring and the connectors as well as the expected electrical characteristics.
When the project requires it, these checks can be supplemented by specific calibration, functional validation or simulation procedures.
The objective is to check the behavior of the harness as close as possible to the conditions in which it will actually be used.
This last step constitutes an essential guarantee before its integration into the vehicle, machine or final system.
Continuity • Compliance • Defect detection • Validation
Reverse Engineering
Rebuilding a harness when the original data is gone
XAP expertise does not stop at the design and manufacture of new looms.
XAP also has a strong capacity in Reverse Engineering, allowing to rebuild old harnesses, which have become obsolete or for which technical documentation is no longer available.
From an existing harness, XAP teams can complete its complete survey, identify its various components and reconstruct its technical definition.
The electrical diagrams are reconstituted, the nomenclatures established and the plans necessary for the manufacture are recreated in order to have again a usable and lasting technical file.
This retrodesign makes it possible to maintain heritage equipment as well as to modernize an existing system or to relaunch the manufacture of a harness whose original data has disappeared.
The harness can thus be reintegrated into a complete digital documentation that meets current industrial standards.
Link architecture and integration
A project? a specific request?
A loom is defined with the functions and equipment it connects. Also discover the XAP Data acquisition solutions, our approach to Protected electrical distribution architecture, as well as XAP harnesses and connectors already available on our online store.
Whether it is to develop a new architecture, to produce a specific beam or to rebuild an existing harness by Reverse Engineering, the XAP design office can accompany you from the definition of the need to the manufacture and control.
Relier architecture et integration
Un faisceau se definit avec les fonctions qu il relie. Retrouvez nos solutions acquisition de donnees et le guide sur l architecture de distribution electrique protegee. Decouvrez aussi les faisceaux et connecteurs XAP.
Faire etudier votre integration electrique par le bureau d etudes XAP